Well, it was a struggle, but I managed to mill the panels and assemble the doors. This was my first attempt at making the raised panel for the doors. That big ol’ bit is pretty scary.
Note: I used a Bosch 1617 2 1/4hp router mounted in the table with the variable speed control turned down as low as it would go.
First thing I realized is my dust port on the router fence was too small. So I decided to shim the fence with a couple of pieces of 3/4 inch melamine coated shelving. I cut each piece to sorta fit the bit profile. That worked out really well. I clamped the pieces to the existing fence using some home made t track hold downs.
Next problem was bit clearance. The bit has to be mounted above the table top. The hole in the router plate is too small for the bit to fit through. After some trial and error fitting, I settled on a piece of 1/4 inch mdf. That gave me just enough clearance to adjust the bit height. I cut a 4 inch hole in the mdf and then fastened it to the router table by drilling two holes through it and the table; one on each side near the front of the table. Two 1/4 – 20 bolts countersunk in the mdf keep it in place. The fence sits on top of the mdf and secures it once the clamps have been tightened.
Checking the fit. Looks good to me.
Four panels ready for assembly.
Here is one door glued and clamped. I let each one sit for 30 minutes before removing the clamps.
I had my favorite shop helper lending a hand with part of the glue up. And yes, Buc-ees house shoes are proper attire when working in my shop! If you travel around Texas, you may encounter a Buc-ees. Cleanest restrooms you can find. We stop at the Madisonville store every time we travel between Houston and Dallas. Bella loves her Buc-ees shoes.
Time to add a little glue to the joint. The mustard bottle was just the right size for her to squeeze.
Good job. She is serious about her work.
Time to “paint” the glue. That is what she called it.
She did a good job of spreading the glue all the way along the joint. Bella likes Titebond glue. :-)
Note: Sometimes during photo sessions, props are needed. That was the case here. We had fun.
Clamp it, girl!
Check the pipe clamp to make sure it is snug. I love getting her involved. Making memories!
All doors have been assembled and the holes for the hinges bored. Time for a little final sanding and then initial installation will follow.
-- Handcrafted by Mike Henderson - Channelview, Texas