Balboa House Doors

[Matthew Springer]

Those look awesome! I may have to go out and buy some tools!

[Jeff Sudmeier]

Man these doors sure are looking great!! Can't wait to see them finished

[Mark Singer]

Jeff,
The last pics are off my own doors in my home . I built those about 5 years ago. The pics show the basic design and jamb andd head details..I am still in just the glue up mode with 4 doors already glued up.

[Andrew Ault]

Mark,

Thank-you for taking the time and effort to post the process of making these doors. I'm learning a lot. I really appreciate the drawings and photographs.

-Andy

[Mark Singer]

I am sorry for the long lags between phases of door construction. I had a dinner party last night and very busy during the days. Because I am making 11 doors in this phase and working on all of them one task at a time....it is dragging a bit.

I will try to show the rabbeting of door for the glass on one door to keep the interest going...I greatly appreciate the strong support this thread has received ...even if you are not building doors, there is a lot of good info on preparing stock and designing jigs that can be used on other projects.

It is interesting that all the work has been done will basic machines ...no slot mortisers or European rip or sliding saws. Tablesaw, Router, bandsaw, jointer. planner...just the normal stuff. I have many friends that make doors for a living and have all the fancy machines....the end product is about the same...if anything mine may be a little nicer...more attention is payed to matching stiles and rails and flattening that really makes for a trouble free door.
Thanks Again and I will keep going....

[Don Baer]

Mark,
We totaly understand that you do have other commitments so don't appologise. I for one am finding this a most facinating thread and am following your progress and learning along the way. I agree about using basic machines and that one of the aspects that I find so facinating about the thread.

Thanks for taking the time and sharing your progress with us.

[Mark Singer]

Thanks for hanging in there... Well I routed the rabbet on one door. I used a rabbeting bit with a pilot bearing and made about 5 passes to reach the center of the door thickness. Any glue or slight offsets should be scrapped or sanded flush prior to routing so the router base has a consistent surface. Your first pass should be a light one and if there is tear out pay attention.....you can climb cut and lower the speed to eliminate it.. The Festool router only has 3 depth posts and there really should be more to quickly adjust for passes.

The corners are then chiseled square and the top edge is the most important since it aligns with the glass stop. The stop should not be mitered ....instead run the stiles full length first and then the rails...this will make the stop almost disappear since it is continuous with the grain of the stile.

So I could actually measure and order glass....I will wait and get it all at once.

[Mike Vermeil]

Mark,

Doors are looking good. Gotta luv that mohagany! I noticed that you're not using the dust collection on the Festool router. I've been thinking about investing in a Festool router in part because of the good things I've heard about the dust collection, and so am wondering why you're not using it. Do you find it cumbersome?

Thanks,
Mike

[Jim Becker]

I've been thinking about investing in a Festool router in part because of the good things I've heard about the dust collection, and so am wondering why you're not using it.

I was going to ask the same question...especially with mahogany which spews forth a lot of nasty fine dust when milling!! I find the dust collection the best thing since, umm...red wine...when it comes to working with the router!

[Mark Singer]

Well,

I will use it...I am just getting used to the router and I will try it on the next door. Jim I know you did a review of this router....why does it only have 3 depth steps on the turret?

I was going to ask the same question...especially with mahogany which spews forth a lot of nasty fine dust when milling!! I find the dust collection the best thing since, umm...red wine...when it comes to working with the router!

[Jim Becker]

Jim I know you did a review of this router....why does it only have 3 depth steps on the turret?

'Can't answer the question, although that's about the same number my other routers have, too...at least working from memory.

[Mark Singer]

Well, 6 doors are clued up and 4 are rabetted for glass. There really is nothing to post because all the techniques are more of the same. I am just in the "mass production" mode. The project seems a little easier than the last time ...better jigs are helping. I will try to order the Mahog. for the jambs. One door I can't do because the ceiling may drop for heating which would reduce the height. The framing is almost complete ...maybe a week or 2 more..

[Mark Singer]

All the doors that I can make are glued up! I have one more and the entry and I am finished...there is still making the jambs, hanging them and installing the stops. The first picture shows matching the stiles....they are cut from one board. The heavier figure of the grain should be at the bottom. The last door I made is the Master Bedroom....44" x 96"...It will have a transem above . Once the heating ducts are figured out , I will know thw height of the Powder Room ceiling and can make that last door.

[John Miliunas]

Mark, you are one lean, mean, door-making machine! I'd still be on my first...maybe second, right about now! Thanks again for the tutorial. Lots to absorb. I especially liked the part about making the router jig. I'll have to go over that one again. Keep us posted...Great job!

[Don Baer]

Mark,
Just a question. Why did you do the rabbiting after the glueup ?
I would have thought it would be easier to do them either on a routertable or a tablesaw prior to glueup. Not questioning your technique, just wondering.