The panels for these doors will be four boards wide. They were milled at the same time the styles were using the same radius jigs. the panels will end up 3/4 thick, the parts were milled a strong 1/32 over that thickness to allow for sanding. A tray was used once again to cut the angle on all the parts on the table saw.
After the angle is cut on both both sides the parts are biscuted a to help in the gluing process. Make sure you keep them back far enough so they do not come out in the profile of the panel.
Then I use a piece of 1” mdf as a clamping pad for the panel. It is cut an 1/8 smaller in width than the width of the panel is when it is fit together. Making the clamp pad narrower than the panel will help in keeping the panel the right radius. It will crush the sides of the panel, but that’s ok. The panel is oversized at this point. Clamping blocks are cut to the outside radius of the panel and full width of the panel. Assemble the panel and clamp it to the 1” piece of mdf along its width. Then take the clamp blocks and clamp them over the top of the panel to the 1” thick mdf under the panel. The pictures below will explain better than I can.
Ok,,,,,,,,,More sanding blocks are made for the inside and the outside and the sanding begins. If you have taken your time and fit things well there sanding shouldn’t be to bad.
Well lets see how we did. Below is a picture of a larger panel that was for the Island, but it was made the same way as our door panels were. The computer drawing is full size, the second line on that drawing is the outside radius of our panel.
TA DA!!! Here’s how it came out.
Running the profile on the panels is next,,,,don’t miss it!
Thanks for hanging with me. We’re getting close to a dry fit.
-- Les, Wichita, Ks. (I'd rather be covered in saw dust!)
13 comments so far
Bigbuck
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1366 posts in 556 days
posted 450 days ago
Very nice Les
-- Glenn, New Mexico
stanley2
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278 posts in 688 days
posted 450 days ago
Keep it coming Les – getting to be part of my regular diet
-- Phil in British Columbia
trifern
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7894 posts in 660 days
posted 449 days ago
Truly amazing craftsmanship. I can’t wait to see more. Thanks for sharing Les.
-- My favorite piece is my last one, my best piece is my next one.
cabinetmaster
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8498 posts in 451 days
posted 449 days ago
Thanks Les. Can’t wait to see how you do the profile. And thanks for the e-mail on my last question. I really appreciate the information you are giving us.
-- Jerry--A man can never have enough tools or clamps
cabinetmaster
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8498 posts in 451 days
posted 449 days ago
Les, I was just going back and reviewing your blog on the rails and I missed something. I can’t figure out how you actually ran the profile on the rails. Will a curved jig on the router table work to make the profile?
-- Jerry--A man can never have enough tools or clamps
Les Hastings
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953 posts in 666 days
posted 449 days ago
Jerry, You can run the profile on the rails on a router table. Just make fence with the outside radius of the rails and make it tall enough so its taller than the profile is by at least an inch or so. I just use a flat fence and free hand the profile on mine. Since it is curved you can never cut in to far. If the profile is to large to run free hand safely then I would make a fence as well. Hope this helps!
Thanks Guy’s
-- Les, Wichita, Ks. (I'd rather be covered in saw dust!)
CessnaPilotBarry
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1263 posts in 595 days
posted 449 days ago
I’ve recently been reading “Circular Work in Carpentry and Joinery”, so your series has been very interesting to me.
Thanks for taking the time and effort to share!
-- - Please help keep Lumberjocks an enjoyable escape by refusing to participate in political discussions. Simply spit out the bait and ignore the thread...
kjwoodworking
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202 posts in 780 days
posted 449 days ago
Thanks for the post. I just checked out your other projects and you do amazing work. Truly a master craftsman.
-- Kirk H. -- http://www.kjwoodworking.com
jeanmarc
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1751 posts in 609 days
posted 449 days ago
THANKS FOR THE POST.VERY NICE JOB
-- jeanmarc manosque france
Dennis Zongker
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1014 posts in 485 days
posted 449 days ago
Excellent post. Love the bessey clamps. You could never have to many clamps.
-- Dennis Zongker
Karson
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25795 posts in 1293 days
posted 449 days ago
Great posting Les
-- What happens in the workshop stays in the workshop. No wait that doesn't sound right. Karson Southern Delaware karson_morrison@bigfoot.com †
Dan Lyke
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607 posts in 1018 days
posted 449 days ago
Awesome, I appreciate the details you’ve got in the pictures, ‘cause I’m going to want to try this sometime soon.
-- Dan Lyke, Petaluma California, http://www.flutterby.net/User:DanLyke
a1Jim
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16624 posts in 470 days
posted 201 days ago
Thats great want to sell a dvd how you did it I’ll be 1st? in line.
Jim
-- Jim from Heirloom Woodshop Southern Oregon