Easiest way to build your own frame and panel cabinet doors - from Ana-White.com
1/2" hardwood plywood
1x3 boards (measuring 2 1/2" in width) preferably hardwood - I use poplar for paint grade
1" and 1 1/4" pocket hole screws
PANEL - 1/2" hardwood plywood cut 5" less in height and width than desired finished door dimensions
RAILS - 1x3 hardwood boards (measuring 2 1/2" in width) cut 5" less in length than the desired finished door dimensions
STILES - 1x3 hardwood boards (measuring 2 1/2" in width) cut to desired finished door dimensions
Please read through the entire plan and all comments before beginning this project. It is also advisable to review the Getting Started Section. Take all necessary precautions to build safely and smartly. Work on a clean level surface, free of imperfections or debris. Always use straight boards. Check for square after each step. Always predrill holes before attaching with screws. Use glue with finish nails for a stronger hold. Wipe excess glue off bare wood for stained projects, as dried glue will not take stain. Be safe, have fun, and ask for help if you need it. Good luck!
It's super important to get this plywood panel cut square and straight. If you can, cut with a miter saw or other fixed saw, or a table saw. If you are cutting with a ciruclar saw, use a straight edge or rip cut to guide you.
Then drill 1/2" pocket holes around the four sides of the panel, about every 8" or so - use your best judgement here. You should do at least two pocket holes per side of the panel.
Next, attach your rails to the top and bottom, through the 1/2" pocket holes with 1" pocket hole screws. The back will be flush and all outside edges must be flush.
Drill 3/4" pocket holes on the ends of the rails for attaching the stiles in the next step.
Finally, attach the stiles to the rails and panel, using 1" and 1 1/4" pocket hole screws as noted in the diagram (1" for 1/2" pocket holes, 1 1/4" for 3/4" pocket holes). All outside edges and back are flush.
Fill pocket holes with either plugs or wood filler.
And that's it!!!
It is always recommended to apply a test coat on a hidden area or scrap piece to ensure color evenness and adhesion. Use primer or wood conditioner as needed.