would it be easier to construct a cabinet door using Stile & Rail or routing out plywood for a mullion look?

Question

just not sure if its easier to cut out the frame in one piece out of plywood or make them via Stile & Rail.
im a novice,.... as im sure you can tell...
,' )
thanks

Answer 1

If you try to use the router to make the "pane" cut outs, youre going to have rounded corners on the inside of the panes.

Depending on the width of those mullions, you may even see some breakage due to voids in the plywood.

If you really want the mullion look, I would go with a framed style of door.... but you can do MITERED frames, instead of Stile and Rail, if the stile and rail bits are confusing. Or use simple mortise and tennon joints, if you want a simpler look... I think you mentioned a "Shaker" influence in one of your questions regarding this project. (Shaker style typically is straight (or tapered) lines... no curves like you would end up with using a router)

For the mullions, I would make them half-lap joints. (Half-lap, is where you cut a notch, in each piece, and then assemble them by placing the notches together.) Rather than trying to cut notches in a bunch of little pieces of trim, I would cut the notch into a wide piece of stock (using the router, or table saw), and then rip the wide stock into narrow strips. You'd need one length for the vertical mullion and another for the horizontal.

An important detail which youve not mentioned yet... are these doors going to be painted or stained? If you like the look of wood, then I'd strongly recommend stain, and using frame style doors (mitered or stile and rail).

If you want to try routing out a plywood panel door, then youre going to need to make some templates. You'll need templates for the face of the door, and a pilot tip (guide wheel) bit for the backside rabbet for the panel. You'll also need to route off the excess thickness of the 'mullions' if you route out individual panes on the front side. (Remember, the panel has to fit on the backside, so the mullions have to be thinner) So, its either remove the stock from the backside, or make seperate mullions anyway... and if youre going to have to make seperate mullions, I'd just go ahead and make the frame style of door.

If youre going to use plywood... make sure you get a good 7 layer ply. It will be more stable, and less likely to curve on you. Poplar plywood would be a very good choice, if you plan on painting these doors, or using a dark stain (cherry for example). There will be fewer problems with voids in the layers too.. something very important to consider if you really want to route out the 'panes' in the doors. I would NOT go to the expense of using a 'veneered' ply (oak face veneer for example), because you are going to be removing MOST of the sheet to make the 'window panes'... its just too expensive.

Have Fun

Answer 2

Easier is a question only answered by the skills and tools that you have.

Are you trying to match a existing door ?

Is it just one cabinet door that you need.

If you want to mimmick a typical mission style door, that is very easy to do, with just a table saw, use a plywood panel as your interrior panel. All straight square cuts, simply dado out your rail and styles to accept the panel.

Cutting a door out of a piece of plywood is likely going to look like, well, look like you cut a door out of a piece of plywood.

Typically, style and rail doors are done with a shaper and using a matched cutter set. If you are making one door, not likely you want to go and buy the cutter set, let alone a shaper if you dont already have one.

There are a myriad of things you can do to closely approximate this with only a table saw if you have to. Sit down and plan out your work. If you also have a router, now you are on your way to doing a improvised style and rail using only these two tools.

If you do style and rail, is your door inner panel going to be plywood or a solid wood raised panel. Again, shaping a raised panel traditionally means a large diameter cutter and a shaper. However, once again, the ubiquitous table saw can help you to closely approximate a nice raised panel. You can bevel the panel by feeding your work oriented against the fence vertically. A steady hand and be careful, this leaves a lot of blade exposed and the work piece is standing up against the fence making it more difficult to control.

Most home stores, lumber centers etc. stock very attractive doors in a variety of styles and their prices are usually far cheaper than if you bought the lumber to build the door yourself. The trick will be to find a door that works for you.

Finally, most medium sized towns have a cabinet shop or three that do custom, or semi custom work. They may have a stock size door they would be willing to sell you as well.