Making a door

[lostintheforest]

hi i have just had to replace a pane of glass today in a door with the same curve on top. the bottom and two sides were beads the top one was one solid piece moulded with the top of the door.

 

[katellwood]

Just made this out of American White Oak

Following the top rail being set out it was cut out on the bandsaw

Then sanded smooth on a sanding block on the spindle

Following this a small rebate block was placed in the spindle with a bearing collar added to the top, the bearing collar being accurately turned on an engineering lathe to give an half inch rebate (i.e. 1" smaller than the rebate block

the moulding on the opposite side was applied with a bearing router

the beads were laminated by using the spindle as a thicknessing sander

then laminated between two pieces of mdf

once glued the thicknessing sander was used to clean up and simension to size

and subsequently moulded with the router

ready for fitting

If you need more info re the actual making of the door let me know

(thanks to motownmartin for showing me how to place images in posts)

 

[MooreToolsPlease]

how did you form the rebate ?

 

[katellwood]

As shown with he rebate block and the turned bearing collar, it works like an extremely large bearing router cutter but the bearing needs to be exactly 1" smaller than the rebate block to cut an 1/2" rebate

 

[MooreToolsPlease]

very clever, how clean is the rebate in the cross grain sections?

 

[katellwood]

pretty good

 

[MooreToolsPlease]

looks great. is this a process you use alot making doors?
one thing that i have been wondering for a while now, is the gun stock stiles your door has, how did you cut them exactly?

 

[katellwood]

A picture paints a thousand words!!!

 

[JFC]

Great to see another Craftsman added to the forum ! That is class work !

 

[Paul Chapman]

Great stuff

Cheers :wink:

Paul