I have a customer requesting mullion glass cathedral doors with four lights. I have been making my own doors for quite some time but I'm not experienced in making the thin wood pieces in mullion doors. I have done them in the past, running the rail/cope cut on a wide board and then ripping it down to about 1 - 1 1/4" wide pieces and running the stile profile by hand on both sides. I then, on my table saw, cut off the back part up to where the panel would insert, and glue the pieces to the door. Does anyone have a better way of making these pieces? And how would they be made on cathedral and arch doors?
From contributor R:
If you are charging what you should for these doors, you could afford to order them from a door manufacturing company and be done with it.
When I can, I like to make a minimal muntin - say 7.5 mm square (or whatever the dimension from the glass face to the door face happens to be for that profile) and notching the sticking. On smaller doors like I prefer to make, it looks less overwhelming than a full profile muntin.