Lesson Room Cabs
In the beginning
3 4 5
6 7 8
12 13 14
Router Table 2
Give Me A Brake
Shop Reno Tenjinsama Shrine Tree Tour
Tod Evan's Doors
Building The Phoenix
The Phoenix Part II
Jean Francious Escoulen
Eli Avisera Demo Day One
Eli Avisera Day Two
Bowl Blank Processing
Captured Hollowing Rig
Logging In Tokyo
3 Woodlot 4
Mill Mk II
Making Doors the Tod Evans Way!
`cause some folks expressed an interest in another thread i`ve
undertaken the chore of documenting how i build doors.
i do both interior and exterior doors the same way construction wise only
exterior doors get weatherstriping, permanent thresholds and instead of pinned
panels i use polyurethane airline to surround the panels to allow for expansion
but still seal out weather.
first off i`ve built doors for various clients per their specs using solid wood,
usually 10/4.....every one of these doors has warped with seasonal
movement.....for those of you who are "purests" these doors where done
correctly, through wedged tennons, mouldings cut into the rails-n-styles and
mitered, ect......they still moved enough with seasonal humidity changes to
cause sealing problems....
now when i`m commissioned to build "solid" doors i take another
approach, one i`ve gleaned from the industry. most of the higher quality
"builder" doors that are stocked locally are of a wheatboard core
that`s been banded and veneered. higher quality "custom" doors are
generally made of fingerjointed fir and banded and veneered with a slightly
thicker skin. the "builder" doors are assembled using 6" screws
in lieu of dowells, whereas the custom units depending on manufacturer will use
stubb tennons and dowells or in the rare instance loose tennons. i`ve not seen
custom doors available that use through wedged tennons........
the method i use now is i glue together a core lamination of the same species as
the face. these cores are glued in blocks 3-1/2" x 10" x length of the
rail + 2-4" for error. after the glue sets i`ll resaw 1-1/2" x
10" blanks from the block, surface them and laminate a 5/16-3/8 face veneer
to the blank. the next step is to dado the rails for allthread, the reason for
dados is that it`s a real bugger to drill accurate holes through the rails...i`ll
stop here `cause that`s how far i am on the doors i`m building....tod
here`s a couple more pics that`ll help explain what i`m
doing.. the first three show a cutaway of the dado and allthread only these
doors will have 10" rails with two pieces of allthread in each rail. mac
the fourth pic shows my big bandsaw without the feeder mounted, that`s a
1-1/4" 3 tooth blade.....yes i bag the faces
here`s an update on the doors.....in-between radiused moulding
and 3-days off last week i still managed to get some work done on the doors.
these are dry assembled with allthread awaiting panels. there will be back to
back panels in both the upper and lower sections and the top of the doors will
curve to follow the radius of the top rail.....