Recessed panel joint cabinet doors are made from five pieces: A panel, left and right stiles, and top and bottom rails.
The manufacturing process begins when raw lumber is graded for color and grain consistency. This ensures that all your doors match the grade you have selected and that your doors will have a consistent look when installed in your project.
Making the Panel
Veneer skins are selected to match the color, grain, and material grade of your frame material. The plywood is cut to size.
Making the Frame
Boards best suited for frames are rip cut to the custom width of the stile and rail width of your cabinet doors.
Frame stock is molded to match the profile of the style you have selected. Molded frame stock is then cut to the lengths required by your custom sized cabinet doors. Knots, sapwood, and other undesirable features are removed to the specification of the material grade you have selected.
A blind mortise and tenon are then applied to the ends of each part.
Butt Joint Frames
Frame stock is cut to length and the inside edge profile is applied to all four frame parts.
The top and bottom rail are then coped to fit within the inside edge profile.
Assembling the Door
Glue is applied in the joints of each part. The panel is inserted into the groove on the inside edge of the frame parts and a clamp is applied to finish assembly of the door. The glue is allowed to cure until the door can be safely handled.
Sanding and Final Inspection
Outside edge details are applied if they are required for your selected door style and boring for hinges is done if requested. Doors are sanded by hand and by machine then inspected for defects before being placed into packaging.