This instructional video was created by Matt from Next Level Carpentry. It covers the complete process of building high-quality flat panel cabinet doors using solid wood and traditional woodworking techniques.
Focusing on clean lines, durable construction, and natural wood character, Matt walks through each step, offering valuable tips that both beginners and experienced woodworkers can appreciate.
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Understanding Flat Panel Cabinet Doors
Flat panel cabinet doors are a timeless choice in woodworking because of their simplicity and adaptability. By using solid wood rather than veneer or MDF, each door showcases unique grain patterns and natural beauty.
For this demonstration, Matt uses rustic knotty alder—a species known for its character marks like knots and bold grain. Choosing solid wood ensures that each door is not only beautiful but also durable and long-lasting.
Material Preparation and Tool Requirements
Matt doesn’t provide a strict material list, but the essential ingredients are solid wood and standard shop tools. A jointer, planer, table saw, and clamps are the foundation for this build, ensuring straight cuts, smooth surfaces, and tight joints.
Working with knotty alder requires a little extra attention. While the knots add visual appeal, they must be positioned carefully to avoid weak spots in the final panel. Selecting boards with attractive grain and stable structure is key to achieving the best outcome.
Milling the Wood for Stability
The process begins by flattening the wood surfaces with a jointer, followed by planing to final thickness. Ensuring the boards are perfectly flat and parallel is critical for tight joinery and a smooth assembly.
Matt emphasizes careful selection and orientation of each piece to take advantage of the wood’s natural features. This thoughtful preparation lays the groundwork for doors that stay stable over time.
Building Solid Wood Panels
Rather than using plywood or veneered MDF, the panels are crafted from solid wood. Matt designs these panels with a raised back profile to increase their strength and reduce the risk of warping.
This technique also adds thickness to the panels, which is important for wider doors that might otherwise cup or twist. Solid panels bring extra durability and a more authentic feel to the finished product.
Sizing the Panels for a Perfect Fit
Once the wood is prepared, Matt carefully sizes the panels, allowing space for seasonal wood movement. Precision in this step ensures that the panels float correctly within the frame without putting stress on the joints.
Proper sizing also ensures that new doors will match existing cabinetry if replacement or expansion is the goal. Measurements are double-checked to avoid issues later during assembly.
Traditional Joinery for Long-Term Strength
Matt uses classic mortise and tenon joinery to build the cabinet door frames. This time-tested method provides strength, stability, and clean alignment across the doors.
Tenons are cut to fit snugly within matching mortises in the rails and stiles. Careful fitting is crucial here, as loose joints can weaken the door over time, while too tight a fit can cause stress and cracking.
Cutting Dados and Fitting Panels
A groove (dado) is cut into the rails and stiles to hold the solid wood panels. These grooves allow the panels to float—meaning they can expand and contract with humidity changes without splitting the frame.
Tenons are sized precisely to fit into the dados without gaps. This attention to detail ensures that the final door will maintain its shape and strength for years to come.
Gluing and Assembling the Doors
Assembly begins by applying glue to all mortise and tenon joints. Matt is careful to leave the panels free of glue inside the grooves so they can move as needed.
Once the panels are slid into place, the frame is clamped securely using staggered clamp placements. This technique distributes pressure evenly and prevents bowing or distortion during the glue-up.
Sanding and Preparing for Finish
After the glue sets, any squeeze-out is cleaned up, and the sanding process begins. Matt starts with coarser grits to remove milling marks, gradually working toward finer grits for a smooth, professional finish.
Special attention is paid to the edges and corners to preserve crisp lines while still softening any sharpness. A well-sanded door not only looks better but also accepts finish more evenly.
Final Installation Steps
With sanding complete, the doors are ready for hardware installation. Hinges, handles, and any other attachments are fitted, completing the build.
Once installed, the doors bring a high-end look to any kitchen, combining beauty, strength, and craftsmanship. Solid wood and traditional joinery ensure that they won’t just look good now—they’ll continue performing for decades.
Wrapping Up the Build
Matt’s method shows that professional-quality cabinet doors are within reach for anyone willing to put care into material selection and traditional woodworking techniques. It’s a project that rewards attention to detail and patience with a stunning, durable result.
For woodworkers aiming to refine their skills, building flat panel cabinet doors is an excellent opportunity to practice joinery, wood movement considerations, and precision assembly.
Watch the full video and subscribe to Matt’s channel: