Well lets try this again. I made a mistake on the first try.
he new boards will not show the seam that was created when glued and sanded.
The new panels were cut to size.
Then they were routed to produce the panel shape. The bit was too large to take all of the material in one pass, there for I used two 1/4" strips of plastic to aid in this process. Both were connected to the table fence to space out the cutting 1/2" from the fence.
Then you run the panels through the router. You want to start with the end grains first to prevent tear out. Do all four sides of the first panel and then do the next panel.
Then its time to remove one of the plastic strips to let 1/4" more of the cutter to be exposed. Here I'm showing you how I removed one strip without messing up the alignment.
Well you should be getting the picture so to speak as we progress though the router.
Then you do the same thing over again and following the same steps.
Now you have completed the panels lets see if they fit in a mock up of the door.
And they are square too.
All thats left to do is glue and clamp.