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DOOR CONSTRUCTION VIEW BASE cABTNET DooR FRoNr vrEw wALL-MouNrED DooR FRoNr vtEw@Base cabinetpanell3' I@Base cabinetFI'@Panel2 layers of7+'Lthick plywoodilil1ilil1t$Ys".lL-J*..,.L@siire [--X |,@ a^l ---z r,' Stub tenonJI267/a"T F,1{| [q'i,;llilxnozlte"liIllil-t LlVz":Deepgroove, cutto fit panelLl/c"Knob13" I@|1.-Iil\F\7e'Lthickglassr-tlT@nritJ 72" Stub tdnonIIIl,^ ll l,'F^t illI-@stir.r! lr_IStubtenonRailBUILD THE DOORS\Vith the cabinet built, work canstart on the doors (DOOR CON-STRUCTIoN vIEw). They havesolid wood r-ails rnd stiles withgrooves that capture plywood panels.Thegrooves llso tnate with stubtenons in the rails to join the frat-ttes.The lest of this project is .tisctttbledwitl-r biscuit joints.Why not thedoor franres? lJiscuits would work,but I prefer stub tenon and groovejoints for a couple reasons.First, e:rcl-r rail and stile needs allroove to receive the door panels.And since you've got to cut a grooveanyway, why not take advar-rtage of it.Second, plate joir-rts need flat nratinssrirflices. That tueaus you d haveto cut stopped grooves on the stiles.MAKE THE PANETS AND FRAMESThe first step is cuttir-rg the rails andstiles (nesn and WALI-MoUNTEDCABTNET DOOR FRONT VIE.WS).Next, cut a celltered groove it-teach piece to receive the PlYwoodprnel. It'.s ersy to do this at the tablesaw if you keep two things in mind.First, '/," plywood usually hasveneer on just one face. I wantedtwo good faces on the Panels, so Igh.red two pieces back-to-back.And '/," plywood isn't quite afull '/r" thick. So cutting a '/."-widegroove means a loose-fitting panel.It\ e.rsicstt-r cttt thc groovc ilttwo passes using a '/r" dado blade inyour saw. Set tl.re dado blade tornake a '/,"-deep cut.Now grab solne scrap stock tl-resarrre thickness as yollr rail and stilerrraterial. Next. adjtrst thc rip fenccso the blade is slightly off center onthe edge of your stock. Then nukethe first cuttins pass (nrc. 4). Nor'vflip the borrd end-for-end andmake another p:rss (rlc. 5).Test fit r panel ir-r the groove. Ifthe groove is too trarrow, nudge theGnce away fror.n the blade ar-rd rrtaketwo l-nore passes. When the panelfits snug withoutbir-rding, you'reready to nrrchine the rrils and stiles.With the lllooves done, the stubtenons can be ctlt olt each rail.Though the tenot-rs are '/r"-1ong,the '/." dado blade can still be usedto cllt thellt.zFllp stockfor second pr@ :'Raise your dadoblade to make amake a pass through your rail or stile.Flip the boadend-for-end andUse a fuatherboad to hold the stock.A miter gaugeextension and therip fence suppodyour rails while cutting the stub tenons.30woRKBENCH tr JANUAI\Y FEBI\UARY 2000