Ogee Router
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Build Your Own Frame and Panel Cabinet Doors for Style and Economy
With the power tools found in a basic shop such as a router and a table saw, a do-it-yourself builder can save money and enjoy creating a practical woodworking project.
Frame and panel construction may be used in a variety of applications including cabinet doors, wall coverings such as wainscot, and furniture such as chests. The structure of a frame and panel system requires five pieces: two horizontal frame pieces or rails, two vertical frame pieces or stiles, and a raised or flat piece that fills the center of the frame called the panel. Decorative trim may be attached to the panel and the top rail for aesthetics. Joining or connecting rails and stiles may employ any one of a number of techniques, depending on the requirements of construction and the inclination and skills of the builder.
For large projects requiring additional strength such as a large door, a skilled cabinet maker may use muntins, or mid-rails and mid-stiles, which subdivide what would otherwise be a large single panel. The rail and stile pieces are thicker than the panel and are consequently stronger. This subdivision of panel size and the use of additional, stronger frame pieces add to the overall strength of the project.
Center panels are fitted to the frame using either a rabbet or a groove. The rabbet is a notch cut into the inside of the frame with a router or table saw and into which the panel is fastened after the frame is assembled. The groove is an incision in the frame, cut with either a router or a table saw with a dado blade, into which the panel is inserted during assembly.
Panels may be flat or raised. Many have decorative molding applied around the border. These options are aesthetic and don't alter the strength of the door. Your skill should be a factor in the complexity of the design. Flat panels, often of plywood, present a flat surface to the outside of the project and are the simplest to make. Raised panels, often of solid stock, may be formed with a variety of designs such as a simple chamfer, an ogee, or cove, using a router or, for some applications, a table saw.
There are numerous options for joining the stiles and rails. A cope and stick router join is fairly common and is made with special router bits that make mirror-image patterns on the edges of the rail and stile. This is an easy join if you are comfortable with your router, but not noted for strength. Generally frame and panel construction requiring strength uses some form of mortise and tenon.
Other joint options may vary in design and incorporate dowels and biscuits, but are similar in function and are simply a matter of choice. In all cases, the mechanical joint should be glued and clamped while the glue dries.
Tools we used for our cabinets included a table saw, router w/router table, clamps, an orbital sander, hand-held sanding block, and hand tools for affixing your hinges of choice. We suggest that a book with illustrations be used for guidance if you are doing this for the first time. Taunton press offers easy-to-follow step by step procedures with good illustrations.
When we built our house, we saved thousands of dollars by building our cabinets, including frame and panel doors. For information, contact us at http://www.grow-cook-eat-beans.com
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