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Ok, it's time to make sawdust. Setup your router with the profile bit you want to make use of. Keep your router setting the similar for all profile cuts in this step. You will cut a profile on each edges of 1 side of both stiles and most sensible and bottom rails. Then on both edges of all sides of alternative two rails. Do now not minimize the rails to length but. I came upon once I started this mission that I must have used my router bit with out the again cutter ( 4th photo ). First photo presentations the profile cut on one edge of 1 aspect. footage 2 and 3 display the results of using 1-1/2 inch lumber and bits made for 1-3/8. Photo two shows the fabric that has been got rid of in picture three. If you have a planer you'll plane the thickness all the way down to 1-3/8, I didn't have one. When your router is about up, reduce a profile on the fringe of a scrap piece of wooden to test for perfection. Router on (*8*) - Material on left when reducing. Always use protection glasses no unfastened clothing and follow all protection precautions.
Now cut a profile on one edge of one aspect of a stile. Check your work and search for defects like photo four that will have to be covered up or cut out. With the width of the material some may also be cut off and then re-cut the profile. I was able to cover this spot up with one of the crucial rails. Continue to chop a profile on each edges of one side of each stiles ( 2- 2X6) and most sensible and backside rail ( 2X8 ). Cut profiles on each edges of all sides of 3rd 2X6 to be used as other two rails. If this isn't clear refer to photo six with notes. Click photograph to look notes.
If you used a profile bit without again cutter you will now have to cut a dado on edge of stiles and rails that have profile cut. Center the minimize or minimize from identical facet of every piece so the dado might be same dimension from face of board. Use a cutter that matches your panel thickness.
Now minimize all four rails to finished period conserving in thoughts that their duration will resolve the width of completed door. Make sure they are all exactly identical length. Don't reduce length of stiles ( 2-2X6 with profile on one edge ) but.