Began work on the upper doors of the Wall Hung towards the end of Episode 19 by creating a bead detail on the right door while telling you of a rebate needed at the left door.
No pics cutting the rabbet, but the center stiles come together just fine.
All four stiles for the upper doors were cut to rough length and grooved for floating panels ‘too long ago’ to remember…
The rail boards were measured and marked for their rough cuts; those are the pieces that need tenons and will be featured in my first iMovie.
The details of the pre-cut panel grooves were transferred to the #198 mortising gauge, then the ends of each rail board were marked accordingly. What I didn’t picture was the marking of the outside cut-offs from said rails; those marks were made with a third gauge so the measure would be steady to all eight board ends.
With all marks made, I could cut the tenons. The boards were clamped one at a time in the leg vise of the bench for work, but before sawing began I registered the cuts to be made with chisels notches. This is (I think) what Schwarz would refer to a the beginnings of a second class saw cut in that these aren’t show joints but accuracy matters, and by notching it’s clear to the saw how to begin.
Setting the notches and making the deep tenon cuts is seen in the longest four minutes you’ll ever spend watching workshop video. And without further delay, here's my first workshop iMovie...
So at the end of the movie were still shots that tried to relay cutting the cheeks of the tenons. The import picture was this one:
Before registering the rail to the bench hook and getting busy with the backsaw, I used the saw to start the cut while the piece extended plenty far from the bench hook’s back fence. Why? So I could see what I was doing, mostly. And it worked wonderfully. Once the cut was started (again channeling The Schwarz saying, “Nibble, nibble, nibble…”), the piece was placed fully into and against the hook and the saw was worked along the marked line to get all straight for the rest of the downward cut. I thought it went well for each of the sixteen cuts made this way, and before you knew it I was ready for mortises.
Oh, wait. These were haunched tenons. Two pictures should make the marking and cutting of those clear, right?
I cleaned them up with a chisel during final fitting as required, FYI…
So, regarding mortise cutting. I used the Steel City and had no issues. Well, some issues. Okay, I broke the mortiser. Twice. First, the cheapo plastic cam that holds the stand-off rod stripped, making adjustments a pliers-required affair. Yuck. Then the ‘shock absorber,’ or compression system, failed in the down position, and when I pulled the head up, it broke free at both ‘yokes.’ Oh well. At least it could be used (and was used) to complete the job. Only one picture of a mortise, and it’s a bad one. Bad picture, that is. The quality of the mortise was fine, as the fit was right on and there’s lots of places for glue to hold.
There were fit checks and adjustments with the #93 shoulder plane, as you would expect, but it wasn’t with too much fettling that the frames came together and thoughts turned to panels. Yes, the panels I glued up last June. Stickered and dusty, sitting on the lower step of the cast Workmate, waiting right where I left them (man, it’s nice having a dedicated shop space!!!)
First I smoothed them with the.. well… I smoothed them.
Then again set the #198 for raising the panels to fit (man, it’s nice having a dual gauge!!!) with the venerable #78 moving fillister plane.
Dry fit and the excitement builds!
Repeat the process on panel number two (oh, and they were ‘bookmatched’ as best I could back when three re-sawn boards made up each panel) and it looks like I’m ready for glue-up of some doors!
BTW, the location of each rail was marked on the stiles as I checked for square.
Glue-up of first door:
Second door glued up:
And some dry time was required… This is what Table Saws are best at, btw, when you have an accurate RAS.
More to come, as next time we’ll be setting hinges, trimming doors to fit and getting the doors swinging! As always, thanks for looking and comments welcome!
-- Don't anthropomorphize your handplanes. They hate it when you do that. -- OldTools Archive