Article
How to Calculate Cabinet Door Sizes
Cutlistor Team4 min read
Introduction
Cabinet door size is not the same as cabinet width. Overlay style, reveal (gap), hinge type, and whether the cabinet is frameless or face-frame all change the blank you cut. Getting this wrong wastes expensive door stock and delays install.
This guide gives shop-usable formulas and examples. Always confirm against your hinge manufacturer's overlay chart when you change brands.
Overlay, Inset, and Reveal
| Style | What the door covers | Typical use |
|---|---|---|
| Full overlay | Most of the case edge / frame | Modern frameless kitchens |
| Half / partial overlay | About half the stile or edge shared by two doors | Traditional face-frame pairs |
| Inset | None of the frame face; sits in opening | Furniture-grade face frame |
Frameless Full Overlay Formulas
- Door width ≈ W - side_reveals (or W - 2×edge_gap, depending on how you treat end gaps)
- Door height ≈ H - top_gap - bottom_gap (or H + overlays - gaps if measuring from opening)
- Document whether W and H are outside case dimensions or clear opening
Paired doors on width W with center reveal R and equal doors:
- Each door width ≈ (W - R - end_gaps) / 2
- Keep both doors identical unless a pull-out or appliance forces asymmetry
Worked Example: 900 mm Frameless Pair
| Dimension | Calculation | Result |
|---|---|---|
| Total door width budget | 900 - 2 - 2 - 3 (edges + center) | 893 mm |
| Each door width | 893 / 2 | 446.5 mm (round to shop tolerance) |
| Each door height | 720 - 3 - 3 | 714 mm |
Round consistently (for example to 0.5 mm or 1/32 in) and match both doors. Confirm hinge boring distance from the door edge per the hinge plate system.
Face-Frame Door Sizing
On face-frame cabinets, doors usually size from the frame opening and the overlay onto the stiles and rails.
Full overlay on face frame
Door width = opening width + left overlay + right overlay. Door height = opening height + top overlay + bottom overlay. Overlays often land near 1/2 in to 3/4 in (13-19 mm) per side depending on hinge and style. Leave a small reveal between adjacent doors that share a stile.
Half overlay
Each door overlays about half of a shared stile. Door width = opening width + overlay_on_outer_stile + half_stile_overlay (per your hinge chart). Two doors sharing a center stile both take half of that stile's overlay budget.
Inset
Door width = opening width - 2×side_reveal. Door height = opening height - top_reveal - bottom_reveal. Reveals of 2-3 mm (about 1/16 to 1/8 in) are common; keep them consistent around the kitchen.
Worked Example: Inset Door on Face Frame
| Door dim | Math | Size |
|---|---|---|
| Width | 14-1/2 - 1/16 - 1/16 | 14-3/8 in |
| Height | 22 - 1/16 - 1/16 | 21-7/8 in |
Drawer Fronts vs Doors
Drawer fronts follow the same overlay rules as doors on that cabinet line. Stacked drawer fronts share horizontal reveals between them. Do not confuse drawer front size with drawer box size; boxes follow slide clearance rules.
Putting Doors on the Cut List and Nest
List each door blank with grain lock, hinge side, and cabinet ID. Nest door stock separately when the finish differs from case melamine. Woodgrain kitchens often nest doors in elevation order for grain flow.
Read the free tier this way: iteration is free, delivery is budgeted. Editing parts and re-optimizing the sheet cost nothing and are unlimited, while PDF export and starting a fresh project draw on 3 per day. The row cap is 20 per list, spreadsheet import is 5 rows per file, and projects are not saved.
Pro is $12/mo with DXF on paid plans for CNC door blanks. Cutlistor nests rectangles; it is not a door design or five-piece door software.
FAQ
Do I size doors from the hinge catalog or from the case?
Both. Case or opening width sets the geometry; the hinge overlay rating and mounting plate set how much of that edge the door can cover. Change hinges, re-check door size.
How do I split an odd-width cabinet into two doors?
Subtract the center reveal (and end gaps per your standard), then divide by two. Prefer equal doors. If a pipe chase forces unequal doors, label hinge sides clearly.
Do five-piece doors use the same outer size?
Yes for the outer blank size that hangs on the cabinet. Stile and rail component lengths are a separate cut list inside that outer size.
Conclusion
Calculate door sizes from opening or case dimensions plus overlay or inset rules, not from cabinet width alone. Lock hinge brand and reveal standards for the whole kitchen, then nest door blanks with grain locks.
Add verified door rows to your Cutlistor job with the case parts and export one production PDF.