The styles have been cleaned up and sanded to 120 grit. Now its time to cut the inside edge of the styles to the correct angle. I use a full size computer drawing to do this but you could draw out the door full size on a sheet of plywood to do the same thing. I never really concern myself with what the angle is. I usaully just take my style and stand it on end on the drawing and mark the front and back where the style needs to cut and connect the dots. That will be close enough for a good starting point. Then I make a tray that the style can ride on laying flat shown in the pictures below.
I take two styles and trim them to angle I have just laid out. (at this point the styles are still about an inch to wide) Then I take them and stand them up on my drawing together and see if they follow the radius of the door perfectly. When I’m happy with angle I go ahead and cut all the styles to that angle on one side only.
Now its time to run the profile and rabbit for the panels on the styles. I apologize I seem to have forgot to take pictures of the process so I’ll explain as best as I can. To run the profile the angled side I just cut needs to run flat on the table when routing or shaping. I usually just put it up against the fence with the edge flat on the table and run it through, but finger boards might be a good idea here. (remember I’ve done this a few times). After that I do pretty much the same thing on a router table to run the 1/4” rabbit for the panel. Setting up a fence and just running it through. Sorry I forgot the pictures on this part.
After the the shaping and rabbiting is done its time to cut the jack miters. Cut all the styles to length, I cut mine tight to the opening the door is going in. The miter is cut using a tray on the table saw. A thin strip of wood is cut to hold the style out away from the fence so the angle on the edge of the style is flat to the tray. I probley do a no, no here, but its the way I do it. I set up both sides of the tray to cut the miters or you need two table saws that tilt different directions. Here’s some pictures of that process.
After the they have been mitered we need to remove the waste. New trays are made to hold the styles at the cut angle, this is a slighty different than the original angle that was cut on the edge of the style. Remember your moving around a circle. The trays are to cut the waste away using the bandsaw pictured below. Remember I’m making two different kinds of doors with two different radius, thats why I have two different trays pictured here. I’ll get back to the glass door later on but the process is the same for both doors right now. However the jigs are slightly different because the radius is different.
Nothing to it,,,,,,,,,,,,next time finishing up the rails.
Thanks for you time!
-- Les, Wichita, Ks. (I'd rather be covered in saw dust!)