Replies

1. 
   saschafer | Mar 07, 2008 01:28am | #1

   Since you're going to want to replace the groove with a rabbet anyway, you should be able to remove the bulk of the panel with a jigsaw, then use a piloted rabbet bit in the router table to remove the remains of the panel as well as the back side of the groove.

   If the panels are floating, you have to take care that any loose panel pieces don't become projectiles as you detach them from the frames. If the panels are glued in all around (e.g., plywood), then you won't have that problem, but you'll have to cut a hair on the deep side to ensure that you remove the vestiges of glue.

   -Steve

    

1. 
   JeffHeath | Mar 07, 2008 02:00am | #3

   Steve

   I remember rabbeting a door to remove a panel just as you described, and shooting the tab leftover from the panel through the wall in my shop.

   A very dangerous proposal, and one that should be considered as very dangerous to perform, as you suggested.

   YIKES

   Jeff

    

2. 
   JeffHeath | Mar 07, 2008 01:56am | #2

   I would never screw with it.  It's too easy to bang out a new set of rails and stiles. 

   A huge concern should be how the rails and stiles are joined on the existing doors.  If there aren't any tenons, removing the wood panel is certainly going to weaken the door's structural strength.  Raised wooden panels add alot of rigidity to the door.  If it's a cope and stick door, without some sort of mortise/tenon-floating tenon construction on the corners, then it's an improperly made door for glass, in my opinion.

   When I make doors with glass panels, they always have a mortise/tenon joinery for additional strength.

   How many doors to you have to make.

   Jeff

1. 
   dlb | Mar 07, 2008 02:15am | #4

   Only 2. My main concern w/ having to make them is matching the finish to the other cabinet doors, but I know I can over come that issue. I will be able to see the doors this Sat. a.m. and I will keep in mind the construction aspects. If you stop and think about it that issue alone is a major one as glass weighs more than wood which implies that the construction of the rails and stiles needs to be more strudy than a door w/ a wood panel.

   Thanks for the input!

   dlb

   .

    

    

   The undisciplined life is not worth examining.

   Edited 3/6/2008 6:19 pm ET by dlb

1. 
   JeffHeath | Mar 07, 2008 07:04am | #5

   As long as you feel confident in matching the finish, then that's definately the way to proceed.  Doors are easy to make if you have the right tools.  You'll be doing a quality job by adding M&T or floating tenons in the corners.  That's what we're all getting paid for......quality.   Leave the hack work to the hacks.

   Jeff

3. 
   hammer1 | Mar 07, 2008 07:26am | #6

   It's pretty easy to remove a panel. You only have to cut the backside of the groove part. Use a router set just a whisker shy, finish with a knife. You will have to secure the door and use a straight edge to guide the router. Panels should be loose, they don't offer any structure to the frame. Four router cuts would be a no brainer for me, especially if I had to match a finish and style.

   Beat it to fit / Paint it to match

4. 
   mrbird90 | Mar 07, 2008 07:28am | #7

   If you elect to rework the existing doors remember some panels have small nails in them to keep the panel from rattling. I reworked a couple of doors using a router to remove the wood for the glass and expose the panel and ran into two nails in each panel. Doors were made by big name, big box , cabinet company.