Crazyraceguy
Member
- Joined
- Oct 16, 2015
- Messages
- 4,887
This is quite the project, far more than I think the bosses thought it would be.
These doors get installed in sets of three. They are 48" wide, with a big rabbet on each side, so they overlap each other. They function as a room divider that opens, to allow access across the opposing sides.
They are covered in really shiny dry-erase board type laminate, and made by a company that specializes in this.
My task is to cut the pockets in the top and bottom of the doors, to accommodate the hardware, and those big rabbets. Plus, the jamb sections for where they meet the walls had to be rabbeted too. Those were just solid Poplar, painted.
I did the rabbets with a single cut on adjacent edges, which takes out a large strip, rather than reducing it all to chips, with a dado set. This is easy with the small jamb pieces, just two passes on the tablesaw.
On laminated doors? not so much. They are way too big/heavy to push across a saw, even a sliding saw.
It has track saw written all over it. The face cuts are easy, especially with a 3 meter rail. The challenge is the cut on the edge.
I built a jig, out of my assembly table. A couple of strips of plywood on the floor act as spacers, both off of the floor and out away from the legs. When clamped in place the door is forced to be square to the table surface. Then a pair of my regular building spacer blocks were clamped through the dog holes and some adjustable ends were fabricated, with the Shaper/Origin. (I love that thing) Finally a piece of 1/2" ply ties it all together and supports the rail.
I thought I took a pic with one of the doors in place, but apparently not?
The real fun of this job is that the rabbets now need to be laminated [eek] and there are 48 of them to do [blink] [blink] two edges of 24 doors. We got 12 of them pocketed and rabbeted today. It took a while this morning to work out the flow, but it got better.
I expected these doors to be fairly light, since they are essentially a torsion box, pine frame with 1/8" MDF skins. That's what I get for thinking. They are at least 100 pounds, in the worst combination, heavy and delicate. Festool Geckos to the rescue. This would have been impossible without something like that. Bending over all afternoon to flip them around would have killed anyone, trying to do it bare-handed.
That's a lot of story, for just a few pics, but more will come, this is only half and I forgot to shoot the jambs, after paint.
These doors get installed in sets of three. They are 48" wide, with a big rabbet on each side, so they overlap each other. They function as a room divider that opens, to allow access across the opposing sides.
They are covered in really shiny dry-erase board type laminate, and made by a company that specializes in this.
My task is to cut the pockets in the top and bottom of the doors, to accommodate the hardware, and those big rabbets. Plus, the jamb sections for where they meet the walls had to be rabbeted too. Those were just solid Poplar, painted.
I did the rabbets with a single cut on adjacent edges, which takes out a large strip, rather than reducing it all to chips, with a dado set. This is easy with the small jamb pieces, just two passes on the tablesaw.
On laminated doors? not so much. They are way too big/heavy to push across a saw, even a sliding saw.
It has track saw written all over it. The face cuts are easy, especially with a 3 meter rail. The challenge is the cut on the edge.
I built a jig, out of my assembly table. A couple of strips of plywood on the floor act as spacers, both off of the floor and out away from the legs. When clamped in place the door is forced to be square to the table surface. Then a pair of my regular building spacer blocks were clamped through the dog holes and some adjustable ends were fabricated, with the Shaper/Origin. (I love that thing) Finally a piece of 1/2" ply ties it all together and supports the rail.
I thought I took a pic with one of the doors in place, but apparently not?
The real fun of this job is that the rabbets now need to be laminated [eek] and there are 48 of them to do [blink] [blink] two edges of 24 doors. We got 12 of them pocketed and rabbeted today. It took a while this morning to work out the flow, but it got better.
I expected these doors to be fairly light, since they are essentially a torsion box, pine frame with 1/8" MDF skins. That's what I get for thinking. They are at least 100 pounds, in the worst combination, heavy and delicate. Festool Geckos to the rescue. This would have been impossible without something like that. Bending over all afternoon to flip them around would have killed anyone, trying to do it bare-handed.
That's a lot of story, for just a few pics, but more will come, this is only half and I forgot to shoot the jambs, after paint.
