How to Make Chipboard Kitchen Cabinet Doors

What You'll Need
3/4 -inch x-2-inch boards (cut to length for stiles and rails)
3/4 -inch wood stock for door panel
Table saw (with dado head)
Drill with 5/16-inch bit
Wood Glue
Bar Clamps
Handles and Door Hinges
Safety Goggles

Chipboard cabinet doors are among the most common kinds of cabinet doors found in houses. Different companies make different kinds of chipboard that can be used for making cabinet doors and the styles range from various colors to various kinds of grains. Follow these steps to build your own chipboard cabinet.

Step 1 – Cut the Wood to Appropriate Lengths

Cut the door stiles equal to the height of the door and rails should, from top to bottom, equal the door width. Then use a dado head in a table saw to adjust the height to a third of the thickness of the wood that you are using for the rails and stiles.

Step 2 – Make the Rail

Fix the auxiliary fence to the table saw and feed a rail face down into the blades of the saw then turnover and repeat.

Attach an auxiliary fence to the table saw, and feed a rail face down into the blades. Turn over, and feed rail into blades again.

Step 3 – Make a “Tenon Cheek” on Rail

Set the dado head of the table saw on ½-inch. Turn each rail on its side and run it into the blades, then turn it over and repeat.

Step 4 – Drill the Holes

Drill holes on the inner edge of each of the stiles, about ½-inch from the ends. Holes should be about 1-1/4-inch deep and 5/16 inch in diameter. Clean them out with chisel to make the mortise. With the ¼-inch cutter, cut the grooves in the sides of the stile between the mortise.

Step 5 – Make Door Panel

Cut a ¾-inch wood piece to the door panel size. If you want a raised panel, set the table saw blade at an angle of 15-degrees and run it against the auxiliary fence on the edge, repeating on all four edges. Then set the blade at an angle of 90-degrees and adjust the blade height to depth of the groove on the stiles and rail and run over the blade on all four edges.

Step 6 – Assemble the Rails, Stiles and Door Panel

Apply wood glue to the grooves and mortises on the rails and stiles. Position the door panel into the grooves. Fix the rails and stiles with the tenon fittings inside the mortises.

Step 7 – Glue Together the Door and Add Hinges

Using a clamp and glue assemble the panel, rail and stiles and join them. Sand the entire door smooth. Add the handles and hinges.

Once you finish, your chipboard cabinet door is ready to be installed and fixed onto the cabinet. You can paint it in any color you want, or use chipboard that is pre-painted.