Stile-and-rail panel construction is actually an ancient tradition, providing stability to keep the panel in plane as it goes through seasonal contraction and expansion. This method divides a door or cabinet front into two primary components: the frame—comprising vertical stiles and horizontal rails—and the panel, which serves as the infill. The method provides structural integrity and a broad canvas for aesthetic detail. The unadorned version of this technique has been called Shaker for the craftsmanship developed by the members of the American 19th century religious movement.
In a stile-and-rail design, the panel “floats” unglued within grooves in the frame, allowing it to expand or contract with changes in humidity without distorting the overall structure. This method minimizes the risk of warping—a common issue in solid wood doors and cabinets.
One critical joinery method is the mortise-and-tenon joint, which ensures a strong and lasting connection between frame components. While specialized router bits are marketed for this task, I’ve found them less reliable due to the high oscillation of the router, which for me ends up looking like the woodwork was chewed by dogs. Instead, as shown in this example I have milled the frame with a table saw and fine finish blade. By making multiple precise passes, I can achieve clean grooves and accurate joints. Although more time-intensive, this approach consistently produces professional-grade results.
