Choosing the wood

Plan to use 1x3 or 1x4 hardwood boards for the door’s frame. You’ll find this material at most home centers and lumberyards. These are just nominal dimensions, of course. The actual dimensions will be 3/4 x 2-1/2 in. or 3/4 x 3-1/2 in.

Store-bought wood has very straight and square edges. For the best results, use the wood in the widths it comes in. Narrower boards ripped from wider ones have a good chance of warping, a problem you won’t be able to fix. Plus, you’ll have a hard time making the new ripped edge smooth, square and crisp, which you’ll need for tight joints. Be picky when you choose your wood. Sight down each piece to make sure it’s flat and straight. If it’s not, your door won’t be flat or straight either, and it certainly won’t close right!

For the panel, look for 1/4-in. plywood that lies flat, but don’t worry if it’s not exactly 1/4 in. thick. Using this technique, that won’t matter. You’ll adjust the width of the grooves to fit the plywood.