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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.