Why Aren’t Your Cabinet Doors the Right Size?

Cabinet doors too big or too small? Learn why sizing issues happen, what’s normal, and how to fix or adjust doors that don’t fit right.

A close-up image of a run of four cabinet doors that appear to have wider gaps than normal. Cabinet doors may be slightly smaller or larger than ordered without it being a problem.

You’ve spent a lot of money on your dream kitchen, but something feels off. The cabinet doors are sticking together. Or maybe there’s a big gap between them. Did someone mess up your order? Are the doors shrinking? What’s going on?

With over 20 years of experience building custom cabinet doors, our team knows what can go wrong and why. We’ve worked directly with hundreds of homeowners just like you who were surprised to find gaps, overlaps, or sizing issues in their brand-new kitchen. But here’s the thing: not every size concern is a problem. Our expertise helps you tell the difference between what is and isn’t normal so you can stop worrying and enjoy your space.

In this article, you’ll learn:

Cabinet Doors Are Rarely the Exact Size You Ordered

Here’s something you might not know – cabinet doors are rarely the exact size you see on the invoice. Most cabinet door suppliers consider small variations – usually just 1mm – normal.

That’s because door suppliers make cabinet doors using wood, machines, and people. And none of those things are perfect; wood moves, machines have limits, and people make mistakes. So, instead of aiming for perfection, cabinet door companies aim for consistency within an acceptable margin of error.

Our team aims to build doors within 0.7 millimetre of your requested size. This tiny range keeps your doors functioning and looking great without stressing over fractions of an inch.

So before you worry that your doors are “wrong,” know this: a slight difference is usually not a sign of a problem.

Many Reasons Cause Cabinet Doors to Be Too Small or Too Big

Let’s explore the most common causes for cabinet doors not being the size you expected.

The Machinery Used for Cabinet Doors Isn’t Perfectly Accurate

Most cabinet door manufacturers use CNC (computer numerical control) machines to size the cabinet doors. These machines are precise but not perfect.

Even brand-new machines often have a tolerance of ±0.7mm. That means if you order a door that’s 12 inches wide, it might come out 11.96 inches or 12.04 inches. And that’s normal.

Our team also follows this industry standard. We use calibrated equipment and verify sizes multiple times during production. But a 0.7mm difference is within spec.

Your Next Step

Ask your supplier about their margin of error. It might be time to ask for a replacement piece if your door is outside of their acceptable margin of error.

A CNC by Biesse. Like many cabinet door suppliers, Cutting Edge uses a CNC router to size your cabinet doors.

Cabinet Door Suppliers Can Make Mistakes

Cabinet door manufacturing is a very hands-on process. Even though cabinet door suppliers use machines, their teams often:

  • Measure each piece of wood
  • Sand and finish by hand
  • Double-check dimensions manually

And sometimes, people make mistakes.

It could be a manufacturing error if your doors are off by more than a millimetre or two. And your supplier should make it right.

At Cutting Edge, we stand behind our work. If a door is outside the expected tolerance, we’ll remake it. No hassle.

Your Next Step

Compare your door to the invoice. Ask your supplier about a replacement if it’s off by over 1mm.

Cabinet Doors Can Shrink and Expand Slightly Over Time

You might notice small changes over time, especially if you choose solid wood cabinet doors.

That’s because wood is a hygroscopic material – it absorbs moisture from the air. In humid weather, wood expands. In dry weather, it shrinks.

These changes can cause:

  • Gaps between doors
  • Doors rubbing or overlapping
  • Size changes months after installation

This movement is normal and not usually covered by warranty.

Your Next Step

If your doors were the right size at installation and changed later, try adjusting the humidity in your home. A dehumidifier or humidifier can help stabilize door size.

Inaccurate Tape Measures Can Make Cabinet Doors Seem the Wrong Size

This one’s sneaky: your tape measure might be the problem.

Older tape measures can become inaccurate, especially if the metal tab at the end is bent or loose. If every door is off by the same amount, there’s a good chance your tool is to blame.

How to test it:

  • Grab a new or trusted tape measure
  • Line up the 1-inch mark at the edge of the door, not the end tab
  • Measure across the back of the door (it’s usually flatter)
  • Compare your measurements to your invoice

Your Next Step

Always double-check with a second tape measure before reporting a size issue.

A close-up image of a tape measure with a red arrow pointing to the metal tab at the end. A loose or damaged metal tab can make your cabinet doors seem too big or too small.

Installation Errors Can Make Cabinet Doors Appear To Be the Wrong Size

Sometimes, the doors are fine, but the installation wasn’t perfect.

Cabinet door hinges have several tiny adjustment screws. If one is even slightly off, the door can:

  • Appear too high or too low
  • Leave a wider gap than intended
  • Rub against the door next to it

Professional installers adjust these hinges during installation, but even the pros can miss something.

Your Next Step

Try adjusting the hinge settings. Look up your hinge model for instructions, or contact your installer for a quick tune-up.

How to Tell If Your Cabinet Doors Are the Wrong Size

Before you call your supplier, check that the size issue is real, and not caused by shrinkage, installation, or your tape measure.

Use This Simple Step-by-Step Checklist:

  1. Grab a good tape measure. Make sure it’s accurate and in good condition.
  2. Flip the door over. Measure from the back – it’s usually flatter and has fewer grooves.
  3. Avoid the end tab. Start measuring from the 1-inch mark, not the metal tip.
  4. Write down the width and height.
  5. Compare those numbers to your invoice.
  6. Check the difference. If the size is less than 1mm different, it’s likely within spec.
  7. Look for signs of shrinkage or swelling. Were the doors once perfect, but now seem off?

If the doors are off by more than 1mm and you’ve ruled out all other causes, contact your supplier.

So… Are Your Cabinet Doors The Wrong Size?

After reading this, you might feel a bit more confident. Maybe the issue is just humidity. Or a tape measure. Or a simple hinge tweak. But if it is a manufacturing error, your supplier should help.

At the end of the day, we’ve all dealt with doors that don’t seem to fit right. This is especially true if you’re living in a humid home, using an old tape measure, or adjusting brand-new hinges. Now that you’ve learned from Cutting Edge Inc. what might cause this, and what’s normal, it’s time to check your cabinet door dimensions and decide whether to contact your supplier.

If you think the problem is outside the acceptable tolerance, the next step is simple: learn how to tell if your cabinet door is covered under warranty.

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