As its name suggests, the shaper -- essentially a router with added power -- is a tool used to shape wood. A shaper consists of a sturdy table and an upright shaft connected to a powerful motor. Its micro-adjustable fence ensures perfect precision cuts. Materials:
Shaper
Raised-panel cutter
Push stick
Square or rectangular wood for raised panel
Open-ended wrench
Stile cutters
Two strips of wood for rails (cut to fit as the horizontal pieces of the door's frame)
Two strips of wood for stiles (cut to fit as the vertical pieces of the door's frame)
Rail cutters
- Install the raised-panel cutter on the arbor of the shaper (figure A). Adjust the fence so that the blade just clears it. This will ensure that the most stock possible will be riding on the fence.
- Turn on the shaper. Using a push stick, pass the square/rectangular pieces of wood through the cutter (figure B). Make one pass for each side of the wood.
- Unplug the shaper. Remove the fence, and use an open-ended wrench to loosen the arbor lock nut (figure C).
- Following the manufacturer's instructions carefully, install the stile-cutter blades, making sure all spacers and collars are in place.
- Reinstall the fence, and raise the stile-cutter blades so that they cut the appropriate profile in the stiles and rails. Send each stile and rail through the shaper once.
- Replace the stile-cutter blades with rail-cutting blades. Use these blades to cut the ends of each rail so that they fit tightly into the stiles.
- After cutting all the parts, glue only the joints where stiles and rails fit together (figure D). Do not glue the panel into the joint: it needs to be able to move.
- Paint or stain the door as desired, and install.
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