I rubber cement the pattern to a piece of hardboard. Unless your printer accepts extra long paper, select the Print Tiled Pages option (File -> Print -> Layout -> Print Tiled Pages). Optionally label the template with its length (15-1/2") and two widths (4-1/4" and 2-7/16"). Either way, you want these ears for safety reasons. Typically I do not bother adding the ears on the paper pattern but I make a mental note to cross cut my hardboard template material 6" longer than the top rail, then I center the pattern on the hardboard. They will extend beyond the ends of the rail, providing a starting point for the template pattern cutter and stile pattern cutter. These "ears" are for safety when routing. Optionally add 3" rectangles at each end of the template. You'll use this to line up the template with the actual top rail work pieces. Add a vertical line the width of the template and center it on the arched template. You can make the raised panel template in the same manner, but instead of creating the arch using the bottom center target point, use the top center target point. Click the left-mouse button and click on "Apply" in the Envelope roll up. Select the bottom center target point and move the cursor up until it intersects with the bottom of your reference rectangle. The rectangle selection changes to allow you to form the arch. Select the double arch icon for catheral doors. Create the arch using the Effects Envelope tool (CTRL-F7). Align the two rectangles to their top edges. Set the V value to your arch height (2-7/16" or 2.4375" in my case). Set the H value to approximately 2/3s the rail length. Select your rectangle and resize it using the Size tool (ALT-F10). Center the rectangle on the page (CTRL-A, Center to Page). Set the H value to your rail length (15.5" in my case) and the V value to your rail height (4.4375" in my case). Size the rectangle using the Transform Size roll up (ALT-F10). Draw an arbitrarily-sized rectangle using the rectangle tool. Set the page size using page setup menu: Layout -> Page Setup. In my case I needed a 15-1/2" wide template, so I set the page size to 16-1/2". Set the page to Landscape and the horizontal size to approximately 1 inch wider than your template length. Launch CorelDraw and click on "Create New Graphic". Here are the steps I followed to create my Single Arch Top Rail and Raised Panel templates: If you use its tool roll ups to set dimensions and angles, the dimensions will be exact. For the money, this program is hard to beat. They're a great buy at $80.00, but I decided I could make my own for nothing. Sommerfeld Tools sells a great set of Arched and Cathedral Arch templates. 
So if your outside door width is 19-1/2", crosscut your rails to 15-1/2". Regardless, if you mill your stiles to the 2-7/16", your rail length is determined by this formula: I milled the stiles to this dimension, but I prefered a much wider bottom rail (4-1/4"). Sommerfeld suggests that you mill the door stiles and bottom rail to 2-7/16". The beauty of the Sommerfeld Raised Panel set is that if you mill your door components to the Sommerfeld-stated dimensions, determining rail lengths and the panel size is a piece of cake. If not, you must attach and remove your top rail template (and raised panel template) two times for each work piece. Something I realized when machining the top arched rail, you really need two router tables. I have a shaper one-piece rail and stile cutter but decided the individual rail and stile bits, such as those in the Sommerfeld set would be a little easier to setup and use. I recently purchased the Sommerfeld Ogee Raised Panel router bit set. Offered in RAUVISIO brilliant, RAUVISIO noir, RAUVISIO shade, RAUVISIO crystal, RAUVISIO terra and RAUVISIO ingrain Glass insert option (Available Spring 2023):Īdd a pre-installed ¼” thick tempered glass center in clear or frosted glass to the finished door.How To: Make Rail and Stile Cabinet Doors Making Rail and Stile Cabinet Doors custom widths for horizontal middle rail or vertical middle stiles (when choosing multiple panels).Offered in RAUVISIO brilliant, RAUVISIO noir, RAUVISIO shade, RAUVISIO terra and RAUVISIO ingrainĬustom option: The custom option allows you to choose the following:
The maximum warrantied size is 30 in W x 65 in H (762 mm W x 1651 mm H), and any height over 48 in (1219.2 mm) requires a center rail. The 3” wide frame (stiles and rails) consists of ¾” thick material and the center panel consists of 5/16” thick material. Our shaker doors are constructed of five separate RAUVISIO panels assembled with REHAU LaserEdge on all four sides.
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