How to build plywood shaker cabinet doors
step by step.
A shaker door is two stiles, two rails and a flat plywood center panel. Here is how cabinetmakers build them, and what to watch for.
What you need
3/4" hardwood for stiles and rails (maple, poplar or birch paint well), 1/4" hardwood plywood for the panel, wood glue, a table saw, clamps and a square.
Steps
- Size the door. Full overlay doors are typically the cabinet opening plus 1" in width and height. Stiles run full height; rails fit between them.
- Cut stiles and rails. Rip 2-1/4" wide strips from flat, straight stock. Cut rails to door width minus two stile widths, plus two tenon lengths.
- Cut the groove. Run a centered groove along the inside edge of every piece, as wide as your plywood is thick and about 3/8" deep. Test on scrap until the plywood slides in snugly.
- Cut the tenons. Cut short tenons on both ends of each rail so they fit the groove in the stiles.
- Cut the panel. Size the plywood to the inside opening plus the groove depth on each side, minus 1/16" for play.
- Glue up. Glue the tenons and, since plywood hardly moves, the panel on all four sides. Clamp and check for square by measuring the diagonals.
- Finish. Sand to 180 grit, prime and paint, or stain. Drill 35 mm hinge cups 3" from top and bottom.
Plywood panel or MDF panel?
Plywood panels are lighter and take stain like real wood. MDF panels are perfectly flat and paint smoother. For painted kitchens both work; for stained doors use plywood with a matching veneer.
Or skip the shop time
A kitchen needs 20–40 doors and drawer fronts. We sell ready-made shaker doors and face frames in five finishes, and complete plywood shaker cabinets from $24.50.
FAQ
What plywood thickness for a shaker door panel?
1/4" plywood is the standard for the recessed center panel. 1/2" feels more solid but needs thicker stiles and rails.
Can I make the whole shaker door from plywood?
Yes, with a flat 3/4" plywood slab and 1/4" strips glued on as a planted frame. It is quicker, but the plywood edges need edge banding or filler before paint.
How wide should shaker stiles and rails be?
Most shaker doors use 2" to 2-3/4" wide stiles and rails, 3/4" thick.