I was commissioned to build all the doors in a client's house including four
barn doors a pocket door and a few bedroom and bathroom doors
I started out by milling the lumber square as usual
this style door has six panels separated by a stainless steel accents trim so I'm
cutting a dado down the length of the Stiles to accept the panels.
each panel will be held in place with a centered tenon the rest of the panel
will be able to expand and contract in the dado
so I am putting stop blocks
spaced out the width of the Tenon's this way I can use a collar on the router to
follow the walls of the dado as I cut as well as stop against the blocks creating
the mortises for the Tenon's
since I have 12 or so doors to build I thought
the quickest way to set up this jig system with the stop blocks was just to
screw them in. So i milled some some wood down to the width of the dado and then
cut them to length. just screwing them in place that way I could quickly pop
them in and pop them out as I moved from door to door.
Here's just a standard panel glue up. I use the Domino just for alignment purposes
well you know that old saying no woodworker ever has enough clamps this
is no exception. with 12 doors to glue up I did not have
enough clamps to glue up all those panels. so as I would clamp them up I
wrote the time on the board. That way I could tell how long they'd been in the
clamps and as I ran out of clamps I'd go back and take the clamps off the ones
that had been in the clamps for at least a half hour. This way I could just keep
going without having to stop
I cut out all the Tenon's on the table saw. That wide of a tenon it took two passes.
I set the fence up for the first pass I did all the panels and then I
move the fence over and then did a second pass to make the width of the
tenon
since the panels are so wide you did not want to glue them full width as this may
cause the panel to split during changes if humidity. so I'm just gluing the
center to add some extra strength. The center of the tenon goes deeper into the
style of your door while the rest just floats in the data keeping it from
cupping. so here I'm just trimming off the excess of the tenon so it will fit
properly. Since this is not a critical cut I'm using a block to move the
workpiece above the fence so I can make all the cuts at one time and not have to
reset up the saw between operations
since the router makes rounded mortises it's easier to round off the tenon than
it is to square the mortise. At least in my opinion.
I always cut my Tenon's a
little bit fat it's easier to sneak up on the tenon and take off more material
than it is to add material back on. I think the easiest way to sneak up on the
fit is just to take a few light passes with the shoulder plane until you got it
it took awhile to do all 12 Tenon's and all 12 doors but each one is a perfect fit
so these are the stainless-steel accent pieces I'm just marking off where I'm
going to put a screw to screw it to the panels that white coating you see is
just a protective layer it gets peeled off later I use the center punch to make
a dimple so there are the drill bit when wander around when it was getting
started. I'm drilling through stainless steel you gotta use a lot of cutting
fluid as soon as that drill bit started smoking it wouldn't drill another hole
to help me Center the stainless steel accent pieces i mocked up a little jig
this helped me hold the panel and the stainless steel in place while screwed
the two together I'm told this protective coating is some sort of PVC
but it's sure seemed more like vinyl it was a huge pain to get off
the scrap pieces of wood that I'm jamming into the stainless steel channel
has Tenon's on the end of them and those Tenon's will slide into the dado and
help keep it all Center while I screw it together. To prevent from having to
pre-drill all these holes to put screws in it I just use self-tapping screws
into the wood worked out great saves a ton of time for a little added insurance
to make sure that panels didn't rattle just in case the stainless steel came
loose or the panel shrank or somehow and they just rattled when you shut the door
I put that some weather stripping in there to take up the space so there
would always be a little bit of pressure against the panels to prevent it from
rattling. since these panels are pre finished before assembly I put a little
blue tape around each tenon to prevent any kind of squeeze out and I'll remove
that blue tape before the glue completely sets just just to make it
easier. I use West's system slow set epoxy to do the assembly for this.
I wanted to make sure I had plenty of time to get all the panels lined up in the in
the stainless steel channels and all the Tenon's in their proper place and
clamped up and square and and all that without having to worry about the glue
setting up on me before I was done. Here I'm just doing a final cleanup before
delivery. That PVC coating left a kind of a weird rub mark on the steel where it
was bent so it a little mineral spirits wiped it right off
And there you have it some custom doors made from cherry with an espresso
colored stain and some stainless steel accents. I think they turned out really
great. We use them for barn doors, your typical swinging door, and some pocket
doors
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