I'm working on a project where I need to make cabinet doors, and I'm looking to do this entirely with hand tools. I've built them before with a router table and various bit sets, the last one being a 'modern Shaker' style that I really liked. I'm just wondering about the best techniques to accomplish this using hand tools rather than power machinery.
7 Answers
I hardly use power tools anymore, as hand tools give me more joy. I once built doors for a Stickley-style project and have a step-by-step photo guide if you're interested!
Fine Woodworking has a detailed article on making cabinet doors. You can read a couple of their free articles before they ask for a subscription. They suggest cutting a shallow rabbet to define the door's field, then planing it down to the right thickness at an angle.
You can check out Matt Estlea's video on making a haunched mortise and tenon joint. He gives an easy way to create a panel with a 1/4" groove on the inside edges.
Oh, I used to watch his tool showdowns! Great guy, need to catch up on his new content.
Robert Wearing has some fantastic articles in 'The Essential Woodworker.' Even if you can't find the book online, a lot of the articles seem to be available everywhere.
For making cabinet doors by hand, a haunched mortise and tenon joint is a great option, along with a plowed groove for the panel. You could create a fixed fence plane to guide your cuts for the door parts. Just remember, doors are one of those areas where hand tools can truly shine since they can replicate the traditional craftsmanship that machines usually can't.
I prefer a full bridle joint over a haunched tenon since it's easier to keep everything coplanar as the wood shifts.
I had issues with my plow plane creating visible grooves from the ends, so I'd like to know how you avoided that too!
Using a haunched tenon is a solid choice. If you want to avoid visible grooves at the stiles' ends, you can chisel them out. I'd recommend a combination plane like the Stanley 45 for your grooves, and using a rabbet plane can help you create those nice edges on your panels.
There's a YouTube video by Paul Sellers that covers making cabinet doors by hand. He often does an excellent job explaining techniques.
Thanks for the tip! I'll check out their site for those articles.