Replies

1. 
   Dave45 | Sep 17, 2007 04:34pm | #1

   What you want to do isn't usually that difficult - but it takes a steady hand.

   Are you sure that your panels are stapled?  Panels usually "float" in the frame so that expansion & contraction won't wreck the rail and stile joints.  Even if yours are stapled, however, you can still remove the panel without wrecking your router bit - if you can see the staples.

   Lay your door face up and measure the width of the rail and stile detail next to the panel.  It's probably has some curves and will be 3/8" - 1/2" wide.

   Turn your door over and mark the detail width on the back of the rails and stiles next to the panel.  This shows you the wood that needs to be removed.

   Set your router up with a straight cutting bit and adjust it to cut ~1/4" - 5/16" deep.  Using an edge guide, plunge cut into the back of the frame and remove the wood you marked earlier.  If you know where the staples are, work around them - you can deal with them later. 

   After the first router pass, you should see the edges of the panel inside the frame.  If you don't, set the edge guide to take a slightly larger (~1/16") cut, and set the depth ~1/16" deeper.  When you have exposed the edges of the panel, use a utility knife or chisel to remove the wood around any staples, then pull them.

   When the panel edges are completely exposed, square up the corners (they will be rounded from the router bit) and the panel should pop right out of the frame.

   Simple, isn't it? - lol

2. 
   GettinTher | Sep 17, 2007 04:43pm | #2

   I replaced the panels in 4 of my cabinet doors with glass.  I simply used a rabbetting bit with the bearing ridiing on the inside edge of the face frame.  I, then used glazier points and clear silicone caulk to hold the glass in place.  I didn't encounter staples. 

   One alternative that may work for youl would be to use a router or even a rotary tool (like a dremmel) with a spiral cutting bit to cut out the panel.  You would use a  straight edge to guide the tool, running the line a little to the outside of the staples and to depth just shy of the face frame.  Ideally, once you did this cut, you wouuld be left with a rabbet for the glass. 

   Make sense?

   View Image

   
   

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   Edited 9/17/2007 9:44 am by GettinTher

   
3. 
   oldusty | Sep 17, 2007 05:22pm | #3

   qb,

         Drill a few 3/8" holes , take your sabre saw from the back side cut out most of the panel , remove the rest  and any metal then router out . Be careful with some grains want to split and get cranky when you rout them in that thin wood .

              good  luck       dusty

   
   

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   Edited 9/17/2007 10:33 am ET by oldusty

4. 
   mrbird90 | Sep 18, 2007 05:29am | #4

   I just did the same job for a client and yes, there were two nails in the panel to keep it centered. The rails and stiles were all the same width so I installed an old blade on the table saw and made cuts parallel to the outside surfaces. I marked the fence to show where the saw begins and ends and lowered the door on to the saw. After sawing, a sharp chisle finished where the saw blade did not cut. The saw blade had to stick up above the table by less than 1/4"

1. 
   GettinTher | Sep 18, 2007 04:26pm | #5

   Dropping down on the table saw.  That's a great idea.