| Cherry and Maple Medicine Cabinet -- Door Completion |
From "Wood Works"
episode WWK-208 |
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Door Completion and Mounting With the case and door frame for the medicine cabinet complete, the door frame can now be fitted with the mirror an back panel to complete it and get it ready to be mounted onto the case.
Materials: Plywood stock for door backing
Pre-cut mirror
Table saw
Vix bit
Block plane
Hand scraper
Cordless drill
Hand router
Chisel
Sharp knife
Brass hinges
Tape measure
Carpenter's pencil
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, saws, drills, routers, etc.
Steps:
- Check the pre-cut mirror to make certain that it fits in the inner rabbet in the door frame. If the mirror is slightly large, the rabbet can be shaved down to accommodate it.
- With the mirror in place, take measurements (figure A) to get exact dimensions for the back panel that will hold the mirror in place.
- To make the mirror back-panel, use the table saw to cut some 1/4-inch maple stock (figure B) to size so that it will fit the precisely into the outer rabbet in the door frame.
- Use a block plane to make any fine adjustments to the size of the panel (figure C).
- Once the fit is snug (figure D), drill pilot holes in the back panel for the screws that will hold it secure in the rabbet. Drill five holes along each side of the panel, and three holes along the top and bottom.
- Before adding the mirror, install the solid-brass hinges that will fasten the door to the case. First, screw the hinges to the case using a vix bit (figure E). Using a vix bit (figure F) with a cordless hand drill will help ensure that the holes are centered precisely.
- Use a sharp knife-blade to scribe around the hinges to mark the positions for the mortises (figure G).
- Use a hand router to cut the mortises for the hinges within the scribed lines.
- Use a sharp chisel to square up and clean out the mortises (figure H).
- With the mortises cut in the case, set the brass hinges into the mortises (figure I), and set the door into position (figure J).
- Mounting the door to the case is fairly straightforward, and follows steps similar to the ones listed above for the case. Use a pencil to make layout marks on the case (figure K), scribe around the hinge, use a router to cut out mortises, then clean up the mortises using a chisel.
- With the mortises all cut, mount the door to the case using the screws that come with the hinges (figure L).
- Earlier, the pieces for the door frame were cut slightly oversized to allow for extra wood in case of inexact fit. Now, the door must be sized exactly to the frame. Use a clamp to hold the door secured to the case, and a scraper to size the door frame so that it is perfectly flush with the case (figure M).
In the segment that follows, the magnetic latch and door handle are added, as well as a wood finish.
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RESOURCES :
Fine Woodworking
A magazine devoted to high-quality craftsmanship in woodworking.
The Taunton Press Inc.
Website: www.taunton.com
The Small Wood Shop (The Best of Fine Woodworking)
Author: Helen Albert (Editor)
Publisher: Taunton Press
ISBN: 1561580619
Woodworking Techniques: Best Methods for Building Furniture from Fine Woodworking
Author: Editors of Fine Woodworking magazine
Publisher: Taunton Press
ISBN: 1561583456
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
The Complete Woodworker's Companion
Author: Roger Holmes
Publisher: Watson-Guptill
ISBN: 0823008665
Advanced Woodworking
Model: 0783539126
Author: Editors of Time Life Books
1998
Time-Life Books Inc.
Website: www.timelife.com
Popular Woodworking
F & W Publications, Inc.
Website: www.popularwoodworking.com
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