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mahogany door

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Project by moonls posted 05-13-2010 03:49 AM 1886 views 2 times favorited 10 comments Add to Favorites Watch

This mahogany louvered door was designed to fit the entrance to an interior boat compartment. The dimensions are 20” wide, 59” high, and 1” thick. I found directions on the internet for making the 2 jigs to rout out the slots in the stiles to receive the slats. I Practiced routing the slots on pine first to make adjustments to the directions which used 1 3/8” thick lumber since my door was only 1” thick. By using a 25 degree angle, I could cut slats that were 1 1/4” wide and 1” apart for proper overlap.

After dry fitting all the pieces, I used a slow-setting waterproof glue to allow time to get all the slats inserted into the stiles as well as the mortise & tenon joints assembled. I didn’t want the glue to start setting up during this tricky process. Finally the door was sanded to 220 grit and finished with 3 coats of spar varnish.

If I make any more louvered doors, I’ll need to construct a better jig that will speed up the routing process. This door had 48 slats which meant aligning the jigs 96 times!

-- Lorna, Cape Cod





10 comments so far

View grizzman's profile

grizzman

7192 posts in 2057 days


#1 posted 05-13-2010 03:57 AM

you did a beautiful job lorna…i love the mahogany…and the building technique is bar none…great job…i got a peek of it from ellen…so i was prepared for your posting…glad you got it posted…your first project…congrats…grizzman

-- GRIZZMAN ...[''''']

View PurpLev's profile

PurpLev

8476 posts in 2402 days


#2 posted 05-13-2010 04:03 AM

this looks fantastic Lorna! the lumber is beautiful, and the finish is spot on.

as for a jig to speed up the process, there are probably several ways to go about it. either routing freehand, or using a router table with an angled crosscut sled and a repositioning fence.

-- ㊍ When in doubt - There is no doubt - Go the safer route.

View ellen35's profile

ellen35

2596 posts in 2186 days


#3 posted 05-13-2010 12:23 PM

Looks as good in pictures as in person!
Very nice work… and a difficult but rewarding assembly.
Ellen

-- "Don't let the perfect be the enemy of the good." Voltaire

View Cher's profile

Cher

936 posts in 1847 days


#4 posted 05-13-2010 06:31 PM

Your hard work paid dividends. Excellent job Lorna.

-- When you know better you do better.

View JAGWAH's profile

JAGWAH

929 posts in 1837 days


#5 posted 05-13-2010 07:38 PM

Norm Abrahms of New Yankey fame made an exceptional jig in one of his episodes. The setup looked like a roe of cheverons that would guide your plunge router cutting both sides at once.
I made the jig and built over a dozen 20” x 72” cypress shutters for a client. I’ll see if I can find more info on it.
The louvre jig made on NYW was in the 2 part program on jigs No 0101 & 0102.
They were the 1st 2 shows of the 13th season.

BINGO check 10 minutes into the video. It is a foriegn site but I found no problem. http://6.cn/watch/783327.html
Here’s one source
http://www.newyankee.com/getproduct.php?0101

-- ~Just A Guy With A Hammer~

View littlecope's profile

littlecope

2972 posts in 2255 days


#6 posted 05-13-2010 08:44 PM

That came out Great, Lorna!! I think Jagwah is onto something… There’s got to be an easier way! :)

-- Mike in Concord, NH---Unpleasant tasks are simply worthy challenges to improve skills.

View Lenny's profile

Lenny

1298 posts in 2280 days


#7 posted 05-14-2010 03:54 AM

Well done Lorna. It looks great. I have never worked with mahogany but most I have seen is darker and more brown in tone. This is lighter and pinkish in color pre-finished and appears more amber or honey colored with the varnish on it. Very nice looking wood. Again, great job.

-- On the eighth day God was back in His woodworking shop! Lenny, East Providence, RI

View Karson's profile

Karson

34916 posts in 3154 days


#8 posted 05-20-2010 02:08 AM

A great looking door. Nice construction.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware karson_morrison@bigfoot.com †

View a1Jim's profile

a1Jim

112937 posts in 2330 days


#9 posted 05-20-2010 03:27 AM

Looks great welll done

-- http://artisticwoodstudio.com Custom furniture

View Dusty56's profile

Dusty56

11688 posts in 2441 days


#10 posted 01-15-2011 06:07 AM

A lot of work for sure , but the end results are fantastic , Lorna : )

-- I'm absolutely positive that I couldn't be more uncertain!

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