There are a number of ways to hold the panel in place. You could cut a rabbet on the inside edge, or you could cut a groove on the inside of the stiles and rails like a cabinet door panel. I chose to stick with the method David Marks used, panel stays. Yet once again, there is an arch to deal with. This time I thought I would just use the top rail as a bending template for a bent lamination to ensure a good fit. The plan was to resaw thin strips 2” wide and just long enough to fit the opening when bent. They would then be cut to fit between the vertical stays. (you can see from the photos how much the panel had ‘greened’ up since the last photos)
After resawing some strips I sent them through the drum sander for a consistent thickness and to remove saw marks.
I then applied Titebond III to one side and bent them in to place using the gate frame as a bending form then applied clamps.
After some time to cook I ended up with a perfectly fitting laminate. I then sliced it in two pieces on the bandsaw, jointed the edges, and ran them, along with the other stays, through the planer.
Then I marked for the precise angle to fit them between the vertical stays. The cutoff sled is proving to be a valuable tool.
I glued and nailed the bottom stays in place, cut the arch in the panel, and put it all together for fitting. More about all that in the next Blog.
-- tim hill www.newcalshop.com