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Old 05-30-2013, 08:59 PM   #16
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How to construct shaker style doors?


I have built a lot of Shaker style doors. For the rails and styles, I use a rail and style bit set with a router. Fast and efficient. If you don't have a router, it is difficult but not impossible to build rail and style doors. Simplest is to use a different joint at the corners, perhaps a mortise and tenon that can be cut using a handsaw and a chisel.

As for the panels, I like to make mine 1/2 inch thick glued up stock, reduced to 1/4 inch at the edges where the panels fit into the slot in the doorframe. I agree with the OPS, a 1/4 inch thick door is too thin for my tastes. If you have a router, you can cut a nice bevel on the edge of the panel, but you can do that with a tablesaw as well. If you are very good with a plane, you can do it that way as well.

As for glueing up the panels, most important is to have a perfectly flat edge to insure the glued up pieces line up properly. You can cut the edge on a tablesaw, or use a jointer, or a plane if you are good. You can also joint the edge using a router table (my favorite way) if you have a tall straight carbide tipped bit (I use a 3" long, 1/2 inch diameter straight bit for this operation).

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Old 05-31-2013, 10:15 AM   #17
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How to construct shaker style doors?


well now there's an idea! Thats near genius! Thanks Daniel! That is a great idea and i just might try that!
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Old 05-31-2013, 12:43 PM   #18
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How to construct shaker style doors?


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well now there's an idea! Thats near genius! Thanks Daniel! That is a great idea and i just might try that!
I thought you said you did not have a router or a table saw? You can get a refurbished porter cable with two bases pretty cheap and they do a lot, and even a Royobi Portable Table saw is not too bad.
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Old 05-31-2013, 03:52 PM   #19
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How to construct shaker style doors?


i meant the idea of gluing another panel to the top of the panel that is in the grooves. It will be cut with a circular, no way around it. as long as i use a guide, my cuts come out straight.
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Old 05-31-2013, 04:00 PM   #20
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How to construct shaker style doors?


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i meant the idea of gluing another panel to the top of the panel that is in the grooves. It will be cut with a circular, no way around it. as long as i use a guide, my cuts come out straight.
What grooves? How did you make the grooves? With a circular saw?

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Old 05-31-2013, 04:03 PM   #21
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How to construct shaker style doors?


i havent done anything yet, but if i have to resort to doing a grooved door, then yes, the grooves will be cut with a circular. Its got an adjustable deck, all i have to do is build a jig to hold the rail or stile in place and clamp down a guide and itll cut grooves just as well as any table saw.
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Old 05-31-2013, 04:05 PM   #22
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How to construct shaker style doors?


im really hoping to find a way around the grooves, but if i have to cut them, so be it. I flat out refuse to pay $15 for a cabinet door, and im not giving up my dream kitchen over something like that.
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Old 05-31-2013, 05:05 PM   #23
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How to construct shaker style doors?


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Originally Posted by TrailerParadise View Post
i havent done anything yet, but if i have to resort to doing a grooved door, then yes, the grooves will be cut with a circular. Its got an adjustable deck, all i have to do is build a jig to hold the rail or stile in place and clamp down a guide and itll cut grooves just as well as any table saw.
That is a very dangerous move, trying to cut a groove on the edge of a 1X with a circular saw is very hard even with a lot of experience.
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Old 05-31-2013, 06:10 PM   #24
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How to construct shaker style doors?


Just turn your circular saw into a table saw. Get a piece of 3/4" plywood sheet and carefully spark up the saw with the back raised. Drop it onto the board so the blade cuts a slice thru the board. Next, screw the saw to the board and then flip the works over and screw the board down to a couple of saw horses and you got an instant table saw. Screw a jbox with a swithched outlet underneath at the front to operate it. If you get creative you can make a t bar to do square cuts and clamp a stop to cut your rails, styles and slots.
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Old 06-01-2013, 11:24 AM   #25
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How to construct shaker style doors?


Please tell me you are not going to attempt this with a battery driven, low torque skil type saw right?

I like the router idea or a real table saw with a dado blade better.
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Old 06-03-2013, 07:30 AM   #26
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How to construct shaker style doors?


Seems to me that the amount of time and stock you'd waste trying to perfect making jigs and converting a circular saw into a table saw would be better invested in a low buck router. It will certainly be safer...... and you'll still own it after the doors are made........ and you stand a better chance of keeping all of your fingers.
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Old 06-03-2013, 10:37 AM   #27
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How to construct shaker style doors?


Quote:
Originally Posted by TrailerParadise View Post
im really hoping to find a way around the grooves, but if i have to cut them, so be it. I flat out refuse to pay $15 for a cabinet door, and im not giving up my dream kitchen over something like that.
you are my kinda dude! I've done so much with a skil saw that is absolutely shunned except in the crazy circle. you master it and you will feel accomplished! the need for fingers arises in this situation though so weigh out the variables accordingly .
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Old 06-03-2013, 02:52 PM   #28
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How to construct shaker style doors?


We attempted the doors this weekend. Lets just suffice to say it didnt work out so well, i even tried your route and rented a table saw, cut the grooves and attempted to make the doors that way and it still didnt work. So, we are back to square one. But i still adamantly refuse to pay $15 a door, so they will be DIY one way or another, i just might have to give up the shaker style
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Old 06-03-2013, 03:42 PM   #29
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How to construct shaker style doors?




Here's a video of a guy building shaker style doors with only a table saw. One of the easiest ones to follow that I've seen.
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Old 06-03-2013, 05:57 PM   #30
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How to construct shaker style doors?


i actually saw that exact video looking for the easiest way to do it. like i said, it didnt work.

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