1) Add a beaded a molding to the inside edge of the frame like this door I found at WalzCraft. The wood and color are not what we want, but the look is. The router bit is a Freud 80-122 with a 1/8in radius. The router bit was $23 from amazon.
2) Use a bridal joint on the shaker frames. I really like to look of this type of mortise and tenon joint and it can built using only a table saw (and jig).
A 14x24 Alder shaker door from BarkerDoor without the design changes is $36.90. Wood for same size door is estimated to cost $11.70. Design changes could easily add $5-10 per door.
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