I am really bad about stopping to take photos.
The picture is taken while standing on a chair. The door is wrong side up with the top of the door closest to the bottom of the picture. The door is actually laying on top of the table saw for ease of access. My back is screaming from trimming the first door while on short saw horses. Live and learn (hurt).
The first door is laying on the floor. Needs one edge trimmed with flush trim router bit.
The second door frame is in progress.
One stile is squared up via the factory plywood edge. Glued, clamped and brad nailed.
Next, the top rail is lined up, glue applied and the pocket screws are driven home. Clamps are applied and then more brads.
Same with the middle and then the bottom rails.
Finally, the opposite stile is aligned, glued and the pocket screws are driven starting again with the top rail, middle then bottom. Clamps applied and more brads.
Purists may notice the luan on the completed door is upside down. This is done for a reason. Pure self satisfaction. I like the “wood” look and since I will be the one looking at it on a regular basis, I turned it this way.
The doors are based on the article published in Fine Wood Working, 2010 Tools and Shops. Interior frame is 1×3, milled from 2×4. The original intent was to use poplar but I didn’t have any to mill and my budget is shot.
Exterior skin is 1/2” bcx.
1×3 interior skeleton frame.
1” EPS white foam sheets in both left and right bays.
Interior skin is 1/4” luan ply.
Due to the budget, I will be holding off on the windows for now. So at the helpful suggestion of my father in law, I put EPS foam in the upper bay also before gluing the 1/4” luan inside skin.
Tomorrow, I will cut the foam for the second door, route the edges flush and install the hinges. Hopefully, I will not screw that up. Hanging on the hinges scares me. Never done it before. Wish me luck. Then, I will go to work for 12 hours. Ugh.
-- If You Haven't Got the Time to Do It Right, When Will You Find the Time to Do It Over?