#Ideas for the Kitchen: Cabinet Door Inserts

Step 1: Decide on new door inset material

Installing new panels in old cabinet doors can really dress up a kitchen (and new panels are a lot cheaper than new cabinets). Insert materials include glass, translucent plastic, copper, metal, fabric, wicker and many others. Adding “feature” inserts to just one or two of your cabinet doors can be striking and very inexpensive. Our homeowners decided to install perforated metal inserts in all of their upper cabinet doors. They initially wanted to use stainless steel to match their appliances, but went with aluminum after discovering that it costs a third of the price and has a similar look (see “Buying Metal Inserts,” below, for tips on ordering).

Homeowner comment:

Photo 2: Rout away the lips

Photo 2A: Close-up of router bit

A pattern bit simplifies smooth door cutting.

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To cut away the lips that secure the door panel (Photo 1), you'll need a “pattern bit”—a straight bit with a bearing that's the same diameter as the cutting diameter. You can buy a pattern bit for about $25, but most are too long to use with a 3/4-in.-thick guide. You may have to shop online to find a shorter bit. One source is routerbits.com. (Search for “3001” to find a bit with a cutting depth of 1/2 in.)

If you're working with just one or two cabinet doors, the only guide you'll need is a straight board. If you have a stack of doors to rout, a more elaborate guide will save you time (Photo 2). The stops automatically position the guide without measuring, and you can rout two sides without repositioning.

Examine the back of the door before you rout. If you find any nails, pull them out so they don't chip your router bit. Before you start cutting, set your router depth so the bit just touches the panel. After you cut away the lips, simply lift out the door panel. The router bit will leave rounded corners at each corner of the door frame; square them off with a chisel or utility knife.