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A shop-made frame-and-panel door built entirely with pocket holes, sized by a fixed formula (rails and panel cut 5" smaller than the finished door) so it scales to any cabinet opening.
| Part | Qty | T × W × L | Material | ✓ |
|---|---|---|---|---|
| Panel (worked example: 24 in x 30 in finished door) Formula: cut 5" less than finished door width and height. | 1 | 1/2" × 19" × 25" | 1/2" hardwood plywood | ☐ |
| Rails (worked example: 24 in x 30 in finished door) Formula: cut 5" less than finished door width. | 2 | 3/4" × 2 1/2" × 19" | 1x3 hardwood boards, 2-1/2" wide (poplar for paint grade) | ☐ |
| Stiles (worked example: 24 in x 30 in finished door) Formula: cut to full finished door height. | 2 | 3/4" × 2 1/2" × 30" | 1x3 hardwood boards, 2-1/2" wide (poplar for paint grade) | ☐ |
| Item | Qty | ✓ |
|---|---|---|
| 1/2" hardwood plywood | 1 each | ☐ |
| 1x3 hardwood boards, 2-1/2" wide (poplar for paint grade) | 1 each | ☐ |
| Pocket hole screws, 1" and 1-1/4" | 20 each | ☐ |
| Wood filler or pocket hole plugs | 2 oz | ☐ |
Overall cost: $. Lumber varies by region, species, and season, so we give a band rather than a figure.
Tools: Circular Saw, Miter Saw, Pocket Hole Jig, Table Saw. Materials: 1/2" hardwood plywood
Cut the plywood panel to 5" less than your desired finished door width and height, keeping the cut square and straight. Drill 1/2" pocket holes around all four sides, spaced about every 8", at least two per side.
Tools: Pocket Hole Jig. Materials: 1x3 hardwood boards, 2-1/2" wide (poplar for paint grade), Pocket hole screws, 1" and 1-1/4"
Attach the rails to the top and bottom of the panel through the 1/2" pocket holes with 1" pocket hole screws, keeping the back and all outside edges flush. Drill 3/4" pocket holes on the ends of the rails for the stiles.
Tools: Pocket Hole Jig, Random Orbit Sander. Materials: 1x3 hardwood boards, 2-1/2" wide (poplar for paint grade), Pocket hole screws, 1" and 1-1/4", Wood filler or pocket hole plugs
Attach the stiles to the rails and panel with 1" screws (for the 1/2" pocket holes) and 1-1/4" screws (for the 3/4" pocket holes), keeping all outside edges and the back flush. Fill pocket holes with plugs or wood filler and sand smooth.