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Building a Custom Door with Trapezoid Glass Accents

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Blog entry by BenhamDesign posted 11-07-2016 10:46 PM 714 reads 0 times favorited 0 comments Add to Favorites Watch

This Blog post is an overview, if you would like detailed info and links to the jigs I used to build this door please visit my personal blog post Building a Custom Trapezoid door and if you would like to see completion pictures please visit my custom furniture website, or watch it be built on YouTube

As with most every project, I started out rough cutting the parts to the general size and milling them to the thickness I need.

I used my shop made tapering jig to cut the top and bottom rails to start the trapezoid shape for the glass accents.

Once I got the angle figured out I cut the middle rails to fit

I used the domino XL with the largest tenons available for the joinery.

I lost some footage/pictures of routing out for the glass panels, but basically I used a rabbeting bit in my router to create a rabbit for the glass to rest in. I went back and chiseled out the round corners to match the trapezoid angle. Then when I install the glass it will be held in place with glass stop tacked with a brad nails.

The jam is a custom size to fit the structure of the bookcase I did plan it out to use an 1 3/8 standard thickness door so I could use standard size hinges and templates.

I used a hinge template to rout out the mortises for the hinges on the jamb and door. This template worked great to be sure everything lined up.

Then to rout out for the strike plate and mortise for the door latch I used another template I picked up on Amazon.

To drill the hole for the door knob I used the standard hole saw kit which is available just about everywhere.

To hold the door on edge, I used a shop made jig comprising of a 2×4 base and plywood triangle supports screwed to the 2×4. It was surprisingly stable

Then when I finish the jamb I build it around the door to be sure that the reveal in the same all the way around.

And finally stained with the customer’s choice of color and installed into the bookshelf

-- What I do in and out of the shop at http://www.BriansBenham.com



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