Hey all. First, thanks a lot to oluf who gave me a tip on how to use silicone instead of spaceballs to keep the panels form rattling. Secondly, this is going to be a long one, so bare with me if interested, if not, no big deal. :)
Raised panel doors are very rare in Europe, so I will have a very posh kitchen when it’s all said and done, so I am very glad. The door with flat inset panels (as classic Euro doors are) looks plain crap when compared to the raised panel one, I know that, since when I turn my raised panel door over, the back side looks very unappealing.
So let’s talk about how to make classy raised panel doors. By the way, I am by no means an expert, so if you see I have done something wrong, feel free to let me know, I am just explaining what I did, not saying it is perfect.
You first start off with your hardwood panels, mine were roughly 5/8” thick.
Then you set up your TS, this is how: you cover your first half of the blade with your fence, making sure your fence’s leading edge is at the dead center of the blade when the blade is raised up to full height. Some people recommend putting your fence at 90 degrees with the blade, but it seemed like a lot more stress than I would like to put on my blade, so I put my “fence” at some kind of angle, probably like 40 degrees or whatever.
Also, it is very important to have a featherboard at the dead center of your blade, so 50% covers the infeed and 50% covers the outfeed side, the reason for that is, that you can’t hold the piece down with exactly the same pressure on all 4 sides, so the featherboard keeps your edges looking crisp. I tried the first by holding down with my hand – the edges varied quite a bit. Also, when you cobble up a fence like I did, plane the edge flat and oil it up with BLO, tung oil or whatever, makes the movement of the panels a lot easier.
Then start going over the edges, first to the endgrain, then do the long grain sides, do all sides on all panels, then raise the blade, rinse and repeat until you are done. I raised my blade up in 1/16-1/8 increments, no real system, just kind of winged it, but make sure that your very final pass will be very shallow like 1/32 or so, that cleans the edges up a bit better.
This is what it looks like when all is said and done. By the way, my panels are maple, and no burns what so ever, which is kind of a success I guess.
After doing all that potentially dangerous shaping on your TS, it is time for safe but boring hand sanding, which oddly enough is when I popped open a cold one + a few later on. On this picture you can see where the hand sanding comes in – everything has been sanded, except the left, long grain side on the right panel. I won’t lie, sanding is a pain, I guess I could have eliminated some of the marks when i used like a 60 tooth blade or something, but I think mine had like 24 or 32 max, but I don’t mind, sanding was OK in the end, sanded it up through 80-100-120 and then ended it there, got bored. :)
Now time for glue up:
Afterwards I sanded the rails and stiles to 180 and the panel to 240, then put BLO on. The BLO is still curing, will lacquer the doors tomorrow. The pictures really don’t do it justice, the grain popped beautifully, after I get them installed I will get a better camera and make some pictures for the last part. Close ups and such.
In the end, for a first test it turned out well, my wife is happy, so that’s what matters. :) If you have any questions I’ll try to answer them the best I can.
-- Measure twice, cut once, cut again for good measure.