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Making Cathedral Doors Napoleon OH

There are a few specialized tools you must have to make cathedral doors. Start with a suitable router table. It should be equipped with a 2-hp or higher variable-speed router that accepts 1/2-in.-shank router bits. You’ll also need a bandsaw or jigsaw for cutting the curves and a set of door-making router bits.

Kurtz Ace Hardware
(419) 592-4488
734 N Perry St, before you order online--call the store
Napoleon, OH
 
Ace Hardware
(419) 335-1717
1495 N Shoop Ave
Wauseon, OH
 
Arps Hardware, Lawn & Garden
(419) 782-1171
1400 S. Clinton
Defiance, OH
 
Northtown Mall
(419) 783-2900
1500 N Clinton St
Defiance, OH
Store Hours
Sears Stores
Store Type
Sears Stores
Hours
Mon:10-21
Tue:10-21
Wed:10-21
Thu:10-21
Fri:10-21
Sat:10-21
Sun:12-18
Store Features
Mon:10-21
Tue:10-21
Wed:10-21
Thu:10-21
Fri:10-21
Sat:10-21
Sun:12-18

Shorts Do it Best
(419) 682-4231
115 W Depot St
Stryker, OH
 
Fastenal- Wauseon
419-335-0758
1369 N. Shoop Ave Wauseon, OH, 43567
Wauseon, OH
 
Fastenal- Defiance
419-782-9591
1503 Baltimore Rd Defiance, OH, 43512
Defiance, OH
 
LOWE'S OF DEFIANCE, OH.
419 782-9000
1831 NORTH CLINTON ST. DEFIANCE, OH, 43512
Defiance, OH
 
Lowe's
(419) 782-9000
1831 North Clinton Street
Defiance, OH
Hours
M-SA 7 am - 9 pm
SU 8 am - 8 pm

Affiliated Cash & Carry
(419) 826-5866
5751 County Road 3
Swanton, OH
 

Making Cathedral Doors

Making Cathedral Doors

A complete recipe for making beautiful cathedral raised-panel doors.

by George Vondriska

Cathedral raised-panel doors are beautiful, but they can be intimidating to make. After many years of teaching students how to make these doors, I’ve got a trick or two up my sleeve to simplify the process and remove some of the fear factor. Here’s a tried-and-true recipe to help you safely and successfully make beautiful doors.

There are a few specialized tools you must have to make cathedral doors. Start with a suitable router table. It should be equipped with a 2-hp or higher variable-speed router that accepts 1/2-in.-shank router bits. You’ll also need a bandsaw or jigsaw for cutting the curves and a set of door-making router bits. The bits and a template set will set you back nearly $400, but they are a big part of what makes this technique airtight. The good news is the router bits are not specific to cathedral-top doors; they can be used to make any frame-and-panel door.

You’ll need a two-piece matched rail-and-stile set (about $135) to make the frame. It’s easier to get good results with a two-piece set than with a one-piece reversible bit. With a two-piece set, you feed all the pieces face down. Reversible bits use one arbor with removable cutters. Some parts are machined face up, others face down. This often results in poor alignment between rails and stiles. Plus, it’s a hassle to have to change cutters on the arbor. Bits with a 1/2-in. shank will produce less chatter and a smoother cut than those with 1/4-in. shank. 


First, cut all the frame pieces (see “Sizing a Door, below”). For a good-looking, stable door, make the frame from straight-grained wood. 

Next, on your router table, set up the end-grain cutter for machining the rail ends. Cutting end grain before long grain helps prevent blow-out on the rails. Here’s a memory device for you: Machine the Rails before the Stiles, because R comes before S in the alphabet.

Mark the back of all the frame pieces. They get machined with their good faces down, so you should be looking at the mark on the back for all the cuts.

Note: Run the end-grain and long-grain cutters at full speed on your router.

Photo 1: Set the height of the end-grain cutter against a test piece in the coping sled. The cut should leave a shoulder on top of the piece that’s twice as thick as the lip on the bottom (see Photo 4). You can tweak the height after a test cut. 

Photo 2: Set the fence even with the face of the ball bearing. A straightedge makes quick work of this job.

Photo 3: Make a test cut, but don’t cut all the way through the test piece. You don’t want to cut into the backer block until the bit height is perfect. That way, the block can be used to quickly set the bit height the next time you make doors.

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