How to Build an Arch-Top Door

For a 1-1/2-in. solid wood door:

* 1x6-in. hardwood strips for rails

* 1-in. hardwood for the stiles

* 1/4-in. and 1/2-in. roundover bits or router bits that profile both sides of material at the same time

* 1/2-in. plywood

* 1/4-in. hardwood plywood for the panels

* 1/4-in. crown molding

* Nails

* Wood glue

* Sandpaper

* Safety glasses

* Ear protection

* Dust mask

* Hammer

* Drill

* Circular saw

* Table saw

* Router

* Chisel

* Clamps

Instructions:

1. Build the door frame. Begin by deciding how large the door needs to be. Then cut four pieces of 1-in. hardwood for the stiles and rails based on the desired dimensions of the door. Each of two shorter pieces will make the top rail and bottom rail. The two longer pieces will make the two stiles. Next, join the stiles and rails at 90° angles with 1-1/4-in. nails. For a door 36 in. wide, attach a cleat of the same hardwood and width (1 in.) across the underside of the top rail. This will help prevent the door from sagging.

2. Cut the plywood panel. Cut a piece of 1/2-in. plywood to the same dimensions as the door frame, or slightly smaller if an overlay appearance is desired. If you prefer a raised-panel look, cut a piece of 1/4-in. plywood for the recessed panel. To do this, cut the plywood piece about 1 to 2 in. narrower and shorter than the door frame's interior dimensions. Center and secure the panel to the door frame using 1-in. nails and thin wooden shims. If desired, cut 1-in. strips of 1/4-in. hardwood plywood for the vertical and horizontal panel moldings. Then nail these strips to the door frame around the raised panel as desired.

3. Create the arch-top shape. Cut a piece of 1/2-in. plywood the same width and about 12 in. longer than the door-frame assembly. Then secure this plywood piece over the door-frame assembly using scrap-wood blocks as spacers between it and the door frame on all sides. Position the top edge of the plywood about 12 in. above the door-frame assembly. Then trace the arch-shaped top from the door-frame assembly to the plywood. Remove the plywood and cut out the arch-top shape using a jigsaw.

4. Attach the arch-top piece. Apply a thick bead of wood glue to the top edge of the door frame and place the arch-top piece on top. Use clamps or heavy objects to hold the arch-top piece in place while the glue dries. Secure the arch-top piece with 1-1/4-in. nails from the underside of the top rail, as well as from the back side of the stiles.

5. Create the molding arch. Cut about three pieces of 1x6 hardwood to a length that matches the width of the arch-top piece, or slightly shorter for an offset arch molding. Then trace the arch shape of the door onto the 1x6 strips and cut them out using a jigsaw. You may need to trim these pieces to fit perfectly. If desired, route a decorative edge on the two outermost hardwood strips. Then glue and nail the hardwood strips across the joints between the plywood and arch-top piece, as well as the joint at the crown.

6. Router the hardwood rails and stiles. Round over all edges of the wooden door frame (stiles and rails) using a 1/2-in. roundover bit. If you prefer, you can use a router bit that profiles both edges of the material at the same time.

7. Sand and finish. Lightly sand the entire door to remove rough spots. Be careful not to sand through the veneer if your door components are of a veneer core construction. Then apply your desired stain and finish.