| Frame-and-Panel Door: Shaping the Panels |
From "Wood Works"
episode WWK-502 |
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Frame and Panels
With the frame and panel pieces all cut, work cab begin on chamfering the edges of the frame pieces and shaping the solid wood panels.
Materials:
Table saw
Table router
Jointer
Power planer
Drum sander
Hand-held router
Gooseneck hand-scraper
Straight-edge
Chalk
Carpenter's pencil
Clamps
Safety glasses or goggles
Note: Cut sizes may vary. For exact measurements, please contact David Marks through his Web site -- information below under Resources. Safety Alert: Always wear safety goggles or safety glasses when working with wood, power-tools, saws, drills, routers, etc. Steps: - Use chalk to mark the edges of the frame pieces for chamfering. Only the edges that frame the panels are shaped (figure A), so for chamfering the edges lay out and follow the marks carefully to avoid cutting through the intersection of the rail and stile.
- At the router table use a 45-degree chamfering bit, raised 3/16 inch, to carefully route the stock (figure B), making certain to stop prior to the marks. It's a good idea to be conservative, and stop short. You can go back and clean up the corners later using a chisel.
- To begin work on the panels (after they have had time to fully acclimate to the humidity of the shop), joint and plane the stock as you did before to ensure that their surfaces are perfectly flat. Next, pass the stock through the drum sander to bring it to final thickness (figure C).
- At the table saw, rip the panel stock to final width (figure D).
- Cut the panels to length using the table saw and cross-cut sled. Leave the panels 5/16-inch oversized in length so that they will fit into the dados.
- With the panels cut to size, the process of shaping them can begin by first cutting a rabbet on all edges and on both sides. Set the fence on the table saw to 3/4-inch, and the blade height to 1/4-inch. Cut the rabbet by first making a scoring cut on each of the four sides of the panel. Start with the end-grain, and then work your way around the panel cutting the long-grain, then end-grain, then the long-grain again. Proceeding in this order helps prevent chip-out.
- Flip the panel and score the other side in the same way (figure E).
- Use an extended vertical fence to support the stock as you finish cutting the rabbet (figures F) on all sides of the panel stock (figures G).
- To give the panel a curved edge, use a 3/4-inch core-box bit at the router table. Carefully set the depth to leave a slight transition line between the rabbet cut and the cove bit. With the bit raised 1/4-inch, rout the cove into each rabbet.
- Once the coves are routed, smooth each one using a gooseneck hand-scraper (figure H). The scraper can be used to remove the transition lines and saw-marks in a single step.
- With all the parts of the door complete, a final dry-fit can be conducted before glue-up begins. Use chalk to mark the center-points of the panels and frames (figure I) to ensure that the panels will be centered perfectly in the frame.
In the segment that follows, the door is glued and assembled, and hardware is selected and installed. Sponsored Resource
Click here to order your tools and materials for this project from Woodcraft!
RESOURCES :
Fine Woodworking
A magazine devoted to high-quality craftsmanship in woodworking.
The Taunton Press Inc.
Website: www.taunton.com
Woodworking Techniques: Best Methods for Building Furniture from Fine Woodworking
Author: Editors of Fine Woodworking magazine
Publisher: Taunton Press
ISBN: 1561583456
Mastering Woodworking Machines (Fine Woodworking Book)
Author: Mark Duginske
Publisher: Taunton Press
ISBN: 0942391985
David Marks Website
David Marks, DIY's Wood Works host, is a master woodworker. For more information on cut sizes and project details, please contact him via his Website at www.djmarks.com
Taunton's Build Like a Pro: Windows and Doors: Expert Advice From Start to Finish (Build Like a Pro)
ISBN: 1561584835
Author: Scott McBride
Order this book from Amazon.com.
The Taunton Press Inc.
Website: www.taunton.com
Installing and Hanging Doors (For Pros by Pros Series)
ISBN: 1561586358
Author: Gary Katz
Order this book from Amazon.com.
The Taunton Press Inc.
Website: www.taunton.com
The Complete Guide to Doors and Windows
Model: 1589230450
Author: Tom Lemmer
(August 2002)
Order this book from Amazon.com.
Creative Publishing International, Inc.
Website: www.creativepub.com
Great Windows and Doors: A Step-by-Step Guide
Model: 0806956038
Author: Rick Peters
(June 2001)
Order this book from Amazon.com.
Sterling Publishing Co. Inc.
Website: www.sterlingpub.com
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