|Project by builtinabarn||posted 02-02-2010 09:20 PM||1974 views||2 times favorited||7 comments|
I had a customer that wanted to take some pre-existing recess panel doors from their kitchen and remove the recess panel to except a decorative glass panel. Here’s how I did it. 1st I set up the table saw so that I could cut into the back side of the door precisely were the dado was that held the 1/4” panel . 2nd, in doing that, my cuts had to stop short so that the kerf did not over lap the kerf come from the other direction. Also I was not able to make the cut in the arch part of the door. 3rd, I used a small laminate router and a straight bit to cut out the corners that I left from the table saw. Next, I removed all the excess wood from the cutting and slide the panel out from under the arch and out of the door frame. Finally, once all that was done I took a router with a rabbet bit that fit the original dado areas of the frame and routed out around the entire back side of the door. This part allowed me to remove the excess wood from the arc and gave me a nice consistent rabbet all the way around the door. Then I inserted the glass into the opening and secured it with some glass clips (or you can silicon the glass in). Hope this helps some of you if you were thinking of doing this for yourself or as part of a job you can supply to your customer.
Oh, and just a note, be sure to find and remove all the screws, nails or staple from the door before doing any cutting or routing.
-- Built in a Barn Bob