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22K views 97 replies 47 participants last post by  KentS 
#1 ·
The deal is...

My good mate Col [ of jewellery box fame] met a couple who are doing up a catamaran… and they started to sand the louvred cupboard doors… made from NZ Kauri BTW…. and then decided that was too much …. and now want to have the whole 16 handcrafted in New Guinea Rosewood… as he is not really setup for door production [and not much NGR ], he took their number and contacted me…I rang them and they came over with all the doors in the back of the car…. A deal was struck and I start today… I will post pics as I progress… Part of the deal was in way of a swap… I varnish all the doors and they give me a Carbatec Scrollsaw… What better reason for buying an Earlex Spray Unit... [available from Carbatec in Australia]
I get to make some sawdust and get two new tools to boot… it don't get much better than that… and I get to work with the amazing NGR…

Meantime the 35 drawers for the Apothecary cabinet have been made and dry fitted ready for gluing … I will then sand the face fronts round on all edges…

There is also a newish board design in the wind… nearly finished it as a matter of fact… just need to rout out the dish in the middle… it will be slightly different to but yet similar to some of my previous work… you will just have to wait for the pics on all of these…

Hopefully tonight ....
 
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#15 ·
Larry,

What are you going to do with a couple of new tools?

Or have you grown a third arm? Yes, that must be it… that's how you get all this accomplished!

Geez, you are a hard worker! Not sure how you get it all done and still have time to eat, sleep, and socialize?!

Have fun with this project.
 
#17 ·
Yesterday...

Here is what I got up to yesterday… first off here are the original doors from the catamaran.


4 larger doors.

6 medium doors.

12 small doors.
Yes I can add too.. was not 16 but a total of 22 doors that had to be replicated… well not the louvre centre…
Not including the 2 small flap doors…

After a hour or so of discussing the design, the clients decided on frame and raised panel construction and to fit the cabinets in with the other timber trim in the cabin…. I will be staining the NGR with an English Mahogany stain… should come up a treat…

So yesterday was … milling, dressing, ripping and cross cutting all the components for the frames…all timber is 19 mm [3/4 "] thick and either 33mm, 45mm, 50mm, 60mm, or 65mm wide…[You convert… lol]


Rough sawn 4/4 stock.

Parts for the smaller doors..

Components for the medium doors.

Rails and styles for the larger doors..
Now that it is today already… off to the workshop and power up the router… cope and stick frame cutting… then some 40 mm thick NGR will be resawn and bookmatched for the fielded panels…

That should keep me busy for a while… I also need to glue up the drawers for the Apothecary cabinet… maybe after lunch… lol
 
#32 ·
Rails and Stiles.

Having dressed all the timber to size… the next job is to make the frame..I use Cope and Stick construction.. also known as Frame and Panel
First using a Mitre Express and Mitre 2000 gauge with stop attached… all the rails [horizontal parts] were cut to size …. this method ensures accuracy… the Stiles [ or the vertical parts of the frame…] are left over long… this means that a little extra protrudes past the rails… these are called 'horns' and enable you to disassemble after dry fitting the panel in the frame…

Then using the two piece rail and stile cutters… [matched router bits make it easier to cut both profiles without the hassle of reconfiguring the cutters in a one piece set…]

I use two routers set up for this… they are dedicated to just cope and stick… makes life easier.

Now using the mitre guide on the router table cut the ends of the rails with the cope profile.
I use a backing board attached to the guide to prevent tear out…



Now swap out bits [ or in my case routers and cut the profiles on the inside edges of all the rails and styles..For the panels I have resawn some 40 mm stock and bookmatched it…


The Magswitch Re-saw Guide Fence makes resawing a breeze.. the timber just rolls along the bearings… no drag no problems…

Unfortunately not only did I break my bandsaw blade while resawing I broke my back up blade… I have ordered new ones but they will be next week before that can be delivered..

Fortunately my Daughter Amanda and Number One Grandson Malakai are arriving this afternoon from New Zealand… Carbatec Brisbane is just down the road from the Airport… so I will be visiting their new warehouse and showroom… I see a blog about this coming up…

Well this morning I will be glueing up the book matched panels.,.. or those I have cut… These too are to be over sized to be cut to exact size after dressing …

More to come
 
#45 ·
Horns on the rails and styles...

I mentioned in an earlier post about making the styles over long.. so that when you dry fit the panel there is a little extra… called Horns… to assist in the taking the frame back apart..
Here is a quick shot of the frame with Horns…

And a few more shots of the book matched pieces that will be cut to size and then milled into the panels…

This last pic is of the rails and styles routed with the other profile not shown in the last post…

I will be assembling the doors in the next few days and then it is off to the boatyard to check the fit… and make any adjustments prior to finish…
 
#58 ·
Mortise and tenon...

Wood Rectangle Wood stain Flooring Hardwood


I know that it is a while since I have posted more on this project… halfway throughout the build using cope and stick frame joinery….change of plan from customer…
Now I have to make the doors with mortise and tenon… so yesterday I cut the 98 mortises and 98 tenons and got ready to bevel the inside edges and cut the groove for the panel…This was after remilling all the frame material..
Good thing though… I managed to book match all the inside stiles for the pairs of doors and cut all the rails so that they flow across the doors…Still a lot more work… which the customer has offered extra payment…
Wood Rectangle Natural material Wood stain Floor


Wood Rectangle Tableware Hardwood Wood stain


Wood Floor Flooring Rectangle Wood stain
 

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#59 ·
Mortise and tenon...

Wood Rectangle Wood stain Flooring Hardwood


I know that it is a while since I have posted more on this project… halfway throughout the build using cope and stick frame joinery….change of plan from customer…
Now I have to make the doors with mortise and tenon… so yesterday I cut the 98 mortises and 98 tenons and got ready to bevel the inside edges and cut the groove for the panel…This was after remilling all the frame material..
Good thing though… I managed to book match all the inside stiles for the pairs of doors and cut all the rails so that they flow across the doors…Still a lot more work… which the customer has offered extra payment…
Wood Rectangle Natural material Wood stain Floor


Wood Rectangle Tableware Hardwood Wood stain


Wood Floor Flooring Rectangle Wood stain
WOW, I DON'T KNOW IF I'D BEEN THAT NICE ABOUT IT. YOU HAVE THE EQUIPMENT THOUGH. NICE SAVE. WHAT A GUY!
 

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#68 ·
Update...profiles.

Taken longer than expected..due to the additional steps to each of these doors…and the fact that I keep putting it off… sidetracked with other projects..

As you can see all the mortices and tenons have been cut…[using the Leight FMT]


I have also cut the Chamfers on the inside edges of the door frames… this was done with a piloted chamfering router bit while the frames were clamped together…


You will also notice that I have taken the time and effort to match the grains both in the styles… and across the rails… these are pairs of small doors…12 all together…

The other doors are all one per opening but I still tried to cut the parts from one piece of timber…

A slot cutting bit was set in the old router table and the groove for the floating panel cut…


These are all done now… just need to cut rebates fore and aft on the panels.. 4 mm at the back and 7 mm in the front and then using a V-groove bit …make a chamfer on the raised panel… When assembled the door will have a Vee profile….

So that is where I am up to….. in the workshop doing a bit more routing…

stay tuned…
 
#81 ·
Final straight...

Coming down the home straight with these doors.

Here is a quick shot of the set up for the slot cutting on the old router table..



Finished the rebates on the panels… back 4 mm and the front 7 mm


Using the Incra Fence and the Woodpecker Unilift made it easy to switch from one height to another …

Moved the blade on the TS to 45 degrees and positioned the fence for the bevel cuts on the front of the panels..



A Wixey Digital Ange Guide is very useful here..

A little adjustment during dry fit and off to the clamps to be glued…



Round out the corners where needed… sand to 240 grit…



Unfortunately due to time constraints I will not be applying the finish or fitting these doors.. this will be left up to the client… but I hope to be able to visit and take a few photos when they are in….
 
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