Entry Doors with side lites

[Warrior]

Yeah! Finally get to see some results. Dry fit time.

Oh yeah, I sealed the endgrain of the panels with some wipe on poly.

Thats me at the dry fit.

A little adjustment and we're ready for glue. I put some glue in the center of the rails for the panel stub tenon.  I have shimmed up the panel so i can just slide the rails and stiles onto it. do not put glue on the stub tenon because squeeze out there would not be appreciated.

My fancy glue applicator ready.

I am mindful not to let glue from the joints get on or squeeze out onto the panel in the corners.

I coat the walls of the mortises and put glue on the tenons as well.

 

[Warrior]

I've got some 12mm ply spacers to ensure the panel stays centered during the glue up.

 

[Warrior]

I take the clamps off and sand the frame to 220

I have the hard pad installed in the RO150
there was a little tear out in the stile and rail so I started at 80 -100-120 in rotex then 120-150-180-220 in RO. Smooth like a baby's butt.

 

[nclemmons]

Beautiful work Eiji.  Thanks for taking the time to walk through the steps.

neil

 

[Bill Wyko]

Eiji, I have to apologize. I thought I had replied to your work. Not only is that a fantastic job but a great use of Festool. I use to be in custom home building, your work brings back fond memories. Great job.

 

[Warrior]

Thank you, Bill. It means alot coming from a craftsman of your caliber.

Eiji

 

[clauer]

These are my doors!  I can't wait to see the finished product.  The instant I saw Eiji's work on the original doors, I knew I found a work of art for my home.  In fact, my Mom liked 'em so much, she decided to get a set too.  Eiji, has she decided on the glass yet?

 

[johne]

And the Oscar for best documented thread goes to......

Once again Eiji great doors, great thread, great pics

 

[blauer]

And, I am the Mother and these pics are my doors also. How exciting to see the production process. I can't wait...and no, I haven't found the right glass yet or hardware. Most interesting thread....nice job.

 

[Warrior]

It's nice to see my clients have checked out the progress on the doors. Since the doors are done I really need to hound B to pick out the glass for her sidelites.

Up next is sizing the doors, building the door jambs and thresholds, making the astragals, and hardware installation.

Next.  Sizing and beveling the doors utilizing the TS75.
          Using the TS75 to rabbett the door bottoms for low profile door sweeps.
          Using the OF1400/OF-FH for hardware installation (hinges and flush bolts)
          MFT and Thresholds and Dominoed door jambs

I also would like to invite any questions and constructive comments.

Thank you,

Eiji Fuller

 

[shayzam]

Wow, those doors are gorgeous!  The choice of wood is beautiful too.  Did you design the doors yourself or was it the design of the owners?

Shayzam

 

[Gary Katz]

Eiji,
Really superb and awesome work, plus the photos, and especially the creative way you took advantage of/and developed specialized uses for the Festool system. I'm overwhelmed. Plus...I didn't see any freakin' dust!

Thanks so much for shooting and sharing all those photographs!
Gary

 

[Warrior]

Did you design the doors yourself or was it the design of the owners?

Shayzam

Shayzam,

Thankyou for the compliments. The client for the original door wanted to emphasize a vertical element in the design since the opening for the pair and sidelites was over 10' and did not want the system to look too wide. I came up with this design and they liked it. The clients for the doors I am building now saw the original set and tracked me down to have some doors built for them.

Eiji

 

[Warrior]

Eiji,
Really superb and awesome work, plus the photos, and especially the creative way you took advantage of/and developed specialized uses for the Festool system. I'm overwhelmed. Plus...I didn't see any freakin' dust!

Thanks so much for shooting and sharing all those photographs!
Gary

Mr. Katz,
I very much appreciate your comments. Coming from my mentor, via your seminars and books, it has the greatest feeling. If any of you finish carpenters out there have not read Gary's book,"Finish Carpentry Techniques" or attended his seminars at a JLC event you are doing yourselves a disservice. When I started out in finish work that book was with me where ever I went.

Thank you,

Eiji

 

[Warrior]

Now I feel old! You look like you are 20 years old or you age very well. This is still a front runner in my mind for the May contest. Actually, it is my first choice.

Comments?

Nickao

Thanks Nickao,

I really need that router right now.
What is the reason that my other thread is not in the running?
Any thoughts on improving this thread?

Eiji

 

[Warrior]

Nickao,

I'm 32 and have 4 gray hairs. ;D

 

[Warrior]

LOL, I've got just 2 kids and 1 wife. I hope it stays that way.

Eiji

 

[Michael Kellough]

Brice,

I am feeling  a bit overwhelmed by the judging criteria. I am doing my best to document this project, but I am neither a photagrapher nor a writer. Now you want to see video? Should I hire a photographer to do this?

I thought this was a project contest and not a documentary contest. In the time I have spent on this thread I could have almost just went out and bought the router.

Eiji

Now you know how Brice feels about doing detailed reviews 

But, I'm with you Eiji, I think the expectaions for documentation have become excessive. You've done a great job on documentation already IMO since it has been more than sufficient to show an exceptional level of design, thought, workmanship, and organization. Especially impressive from someone with only 4 grey hairs. 

Keep up the great work, your clients are lucky to have found you.

 

[Mirko]

Brice, and others, (but mainly Brice) I do not feel you are being fair with Eiji, the criteria needed to post in this "contest" is a joke, and I'm staying far away from the criticism displayed here. Eiji has done enough.
You can not tell people what to do, lead by example, why don't you, show us documentation of work you have done for upscale clients.

Mirko

 

[joraft]

This could be look at as if I'm being a jerk, but I would think after all of the effort that I have given this site the members would understand my intent.

I get it, Brice.

When I first read your suggestions to Eiji, my immediate reaction was: "Wow, winning this contest isn't going to be easy!" But I later thought: "Why should it be?"

You're obviously a perfectionist who puts a lot of thought and effort into everything he does. And there are many around here with a similar mindset, including Eiji. Rising above such a crowd SHOULD take extra effort. Eiji's certainly up to the challenge, it's just a matter of how badly he wants that MFK 700. 

On the other hand, we could always run the monthly contests more like it's done over at WoodWhisperer. You answer a (VERY) simple question and toss your name in a hat. But, the majority of members here indicated they wanted something more substantial. And I think as a group, we will benefit more from going that way.

John