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Making Raised Panels with Horizontal Router Bits

Illustrations and photos in this instruction sheet show the raised panel being made from a 3/4” thick piece. When using this thickness, you must back cut the panel as shown in Illustration (1).

 

Normally a raised panel is made from 5/8” thick material, thus eliminating the need for a back cut.

We used the 3/4” material to show how you can make the back cut with the same panel raising bit, thus eliminating the need to purchase a special router bit to make the back cut.

We do encourage you to purchase a glue joint bit, if you do not already own one. This bit will allow you to make up larger raised panel doors using smaller strips of material, thus gaining a tremendous increase in strength by using a glue joint bit. You can also alternate the growth rings when you glue up the panels, thus increasing the resistance to warping.

Setting Up to Cut Raised Panels

Illustration (1) shows how to set up the router bit in order to make the back cut on the thicker material. Run this panel with the bit approximately 1/8” above the table top and cut all four sides of the panel, on both sides of the panel. This will not only give you the back cut but will start the removal of stock on the face side. Although you can cut the panel in one pass, it is recommended that you make this cut in about 3 passes. This will give you a smoother cut with less finishing to be done to the final cut. 2-1/2 H.P. is the minimum router size recommended. Run bit between 9,000 & 12,000 RPM.

Illustration (2) shows a completely cut panel, done in three passes, increasing the bit height with each pass. Look for the detail on the front of the panel as well as reducing the edge of the panel to slightly less than 1/4” in thickness to allow for easy insertion into the stile and rail assembly.

Finishing

This seems to be the area where most beginning woodworkers have the most trouble. The panel’s edges, especially the end grain must be sanded to perfection at this point. Any roughness left here will be guaranteed to show up in the finished product. A rough raised panel will catch dust and be difficult to clean. It will also catch lint from the dusting rag. Believe me, it will come back to haunt you.

I use both mechanical sanders, such as a random orbit sander as well as considerable hand sanding on the edges of these raised panels. When using a random orbit sander, be careful not to round over the detail edges of the panels. After I am satisfied that the panel is the very best I can get it, I will then stain the panel prior to constructing the door. This will insure that the stain will cover the edges of the panel completely, thus assuring against that unstained line that is sure to appear when the panels change size with the humidity. Be sure to allow the panel to float in the frame. This is necessary to insure against splitting. A brad will hold a loose panel in place.