Building A Trapezoid Door

In this episode of Custom Doors, I build a Custom Trapezoid Door.  We remodeled the client’s Colorado Springs house with new millwork and custom furniture, including a built-in bookshelf as a room divider.  To get to the other side, the client wanted a custom door with frosted glass to be the pass-through between the two spaces.  The bookshelf and door are made from maple with a custom stain to go with the home’s decor.

Building a Custom Glass-Accented Bookcase: A Step-by-Step Journey

Every woodworking project starts with a vision and a rough plan. In this build, I set out to create a custom bookcase with elegant frosted glass accents and a perfectly fitted door. Here’s a breakdown of how it all came together.

Step 1: Rough Cutting and Milling

As with most projects, I began by rough-cutting the boards to size and milling them to the desired thickness. Precision at this stage ensures consistency throughout the build.

Shaping the Trapezoid Design

To achieve the distinctive trapezoid shape for the glass accents, I used my shop-made tapering jig to cut the top and bottom rails. Once the angle was determined, I cut the middle rails to fit seamlessly.

Joinery with the Domino XL

For strong, reliable joinery, I relied on the Domino XL with the largest tenon available. This tool makes quick work of alignment and ensures a sturdy frame.

Routing and Installing the Glass Panels

(A bit of footage was lost here, but here’s how it went!)
I used a rabbeting bit in my router to create a recess (rabbet) for the glass panels to sit in. After routing, I chiseled out the rounded corners to match the trapezoid shape. The glass was then secured with glazing points and small brad nails.

Custom Door Jamb & Hinge Installation

The jam was custom-sized to fit the bookcase structure. To simplify hardware selection, I designed it to accommodate a standard 1 3/8″ thick door, allowing the use of off-the-shelf hinges and templates.

For hinge mortising, I used a Porter-Cable hinge template, which made alignment effortless. The kit included a ¼” chisel to square up the mortise corners for a perfect fit.

Pro Tip:

To comfortably work on the door edges, I built a simple shop-made jig—a 2×4 base with plywood triangles screwed in for support. It was surprisingly stable and effective!

Installing the Door Hardware

• Doorknob Hole: Drilled using a standard hole saw kit (available at any hardware store).
• Strike Plate: A template ensured the mortise was cleanly rounded to match the door’s strike plate.

Final Assembly & Finishing Touches

• The doorstop was glued and nailed in place with headless pins.
• The jamb was built around the door to ensure even reveals on all sides.
• Finally, the piece was stained to the customer’s preferred color and installed into the built-in bookshelf.

Tools & Materials Used:

• Domino XL (for joinery)
• Router with rabbeting bit (for glass panel recesses)
• Porter-Cable hinge template (link here)
• Shop-made tapering jig & door support jig
• Standard hole saw kit (for doorknob installation)

This project was a great exercise in precision joinery and custom fitting. The glass accents add a touch of elegance, while the flush door installation ensures a seamless look.

More Project Build Videos

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Doors

Trapezoid Custom Door and Built in Bookshelf

Barn Door Made from Barn Wood in Steel Frame

Mountain Contemporary Front Door

Custom Door with Stainless Steel accents

Copper Entry Door with a Swoosh

Greene and Greene Style Entry Door