Building Custom Cabinet Doors

1. Buy dimensional 3/4″ poplar boards.
2. Plane to uniform thickness.
3. Rip 2″ and 3″ strips on the table saw.
4. Two dado cuts on table saw for 1/4″X 3/8″ panel groove.
5. Run each section on router because table saw is a POS and there is depth variation in all the grooves…
6. Threaten table saw with large iron maul – mean it.
7. Grumble a little.
8. Cut door stiles (sides) to length – Measure opening for stiles, subtract 4″ for stile width and add 3/4″ for double 3/8″ panel slot.
9. Write all measurements down on a non-descript sheet of paper.
10. Put measurements somewhere safe.
11. Take a 2 week to 4 month break because life gets busy.
12. Lose paper with measurements.
13. Tear house and shop apart looking.
14. Give up and re-measure.
15. Cut rails.
16. Lay all parts out and label, check sizing, trim two pieces, and pray a little.
17. Set up horizontal drill press to drill for dowel joints.
18. Screw up at least 4 initial holes.
19. Hit head in shop at least 3 times.
20. Build sweet dowel trimming jig for table saw – let head swell a little.
21. Cut 3/8″ off each dowel (8 per door).
22. Drill 16 holes per door.
23. Sand the cut-off end of dowel.
24. Dry fit first door.
25. Success!
26. Get out every bar clamp, hand clamp, and Quick-clamp that you own and set up clamping station.
27. Find original measurements for doors in the “safe place.”
28. Say dirty words very loudly. Repeat.
29. Add glue to dowels and joints and assemble door.
30. Apply judicious blows from wooden mallet to seat parts.
31. Get glue on hands and in hair.
32. Clamp up.
33. Wipe extra glue on door off with wet rag.
34. Repeat last 6 steps 8 more times.
35. Scrape clue, plane joints, and sand doors with 3 different paper grits.
36. Check and adjust door fit to openings and prime after more planning.
37. Re-prime and paint with two coats of white cabinet paint.
38. Mark, mortise, and install hinges on door.
39. Install red glass pulls.
40. Mark and mortise hinge/door onto cabinet.
41. Check fit and adjust 2 to 9 times.
42. Repeat steps 28 thru 41 eight more times
43. Drink three beers and swear to never build your own kitchen cabinets from scratch ever again!

Leave a Reply

Your email address will not be published. Required fields are marked *