When it is working, this door does one simple job well: it fills the empty opening left by a cabinet door that went missing from a kitchen. The maker copied the dimensions of the original door and built a shaker-style frame-and-panel replacement, with two stiles, two rails and a recessed center panel. Set side by side against the old door, the new one reads as a very close match, and it sits fitted into the cabinet base awaiting paint.
The construction follows a clean sequence. Solid stock gets rough-cut on a Bosch compound miter saw, then the stiles and rails are ripped to width on the table saw. Grooves run along the inside edges of the frame members to hold a thin plywood panel, and tenons are formed on the rail ends using a wooden box jig with a stop block clamped to the table saw. Assembly relies on Titebond glue and bar clamps.
A few details stand out to me. The original door was measured with a tape measure and the dimensions were written on a wood scrap, which seems like a tidy way to keep numbers at hand. The mortises were cut and adjusted until the panel fit, and excess glue was wiped away using sawdust during glue-up. The panel slides into the grooved frame, the bottom rail goes in last with glue, and bar clamps hold the whole thing.
Two things remain open. The door is light-colored unfinished wood, with painting still ahead. And the order of operations raises a question: parts are cut to final length only after the grooves are made, and the maker admitted this is simply a habit learned long ago and never questioned.
Project by timbercomb. Watch it on their YouTube channel: