In this article I will discuss some ways a person having the basic shop tools can build his own kitchen cabinet doors or China cabinet doors or even curio cabinet doors.
[diagram deleted] To start with, the easiest cabinet doors to make is a slab door made from plywood or MDF with the edges rounded over or profiled and a square pattern routered out in the center. When purchasing the plywood or MDF always buy a sheet that lies flat on the pile. This should give fewer problems with warping.
Similar to this style would be the same plain plywood or MDF with a small molding nailed and glued in the form of a pattern on the face of the door, such as shown on the left. Going a bit further, instead of routering a profile on the edge of the cabinet door, you could apply a small molding on the edge similar to applying square edging or tape. This is particularly useful to hide the grain of plywood. Keep the molding flush with the back of the cabinet door. I used this design with melamine, trimming it with oak molding. MDF, if painted, is an ideal material for cabinet doors since no grain appears on the edges. Be careful to include the thickness of molding in your measurements when cutting the cabinet door to size. The cabinet door should overlap the face frame or gable by about 1/2" to 5/8", depending on the hinges you have chosen.
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