11-20-2016, 03:01 PM
Here's link to Part 5. With the arch jamb and door stop made I moved on to the door components. I made the 4 stiles and two lower rails needed for the two doors in the same manner as for the rectangular door. For the arched rails I started by making two templates from 1/4" plywood. I rough cut the radii on the bandsaw and then used my oh so nice Stanley #113 compass plane to smooth both the inside and outside curves to the layout lines.
In order for the clamps to stay at 90° with the stiles the core of the arch needed to be almost 16" wide. So I glued up a big piece of LVL then rough cut the inside curve. I also rough cut the hardwood edge that needs to be glued to that curve. Then I attached the templates to each piece and smoothed the mating edges on the router table with a large top bearing bit.
My J/P is only 14" wide so I had to cut off a portion of the core to be able to joint/plane the core + edging to final thickness. I did that now, which made clamping the edging in place easier.
When the glue had dried I jointed and planed the rails to final thickness, 1-1/2" inches. Then I attached the template again and routed the outer edge of the hardwood piece smooth.
There were a few bumps on that edge - should have used MDF for the template. So I took a few swipes with the compass plane to remove those bumps. It really is the perfect tool for this job, working from the ends to middle to avoid tearout.
With the cutoffs laid back in place, this is how the arched rails look now.
Next up, veneering the rails and dimensioning the stiles and rails in preparation for cutting the joinery. Thanks for following along.
John
[url=https://forums.woodnet.net/showthread.php?tid=7325245][/url]
In order for the clamps to stay at 90° with the stiles the core of the arch needed to be almost 16" wide. So I glued up a big piece of LVL then rough cut the inside curve. I also rough cut the hardwood edge that needs to be glued to that curve. Then I attached the templates to each piece and smoothed the mating edges on the router table with a large top bearing bit.
My J/P is only 14" wide so I had to cut off a portion of the core to be able to joint/plane the core + edging to final thickness. I did that now, which made clamping the edging in place easier.
When the glue had dried I jointed and planed the rails to final thickness, 1-1/2" inches. Then I attached the template again and routed the outer edge of the hardwood piece smooth.
There were a few bumps on that edge - should have used MDF for the template. So I took a few swipes with the compass plane to remove those bumps. It really is the perfect tool for this job, working from the ends to middle to avoid tearout.
With the cutoffs laid back in place, this is how the arched rails look now.
Next up, veneering the rails and dimensioning the stiles and rails in preparation for cutting the joinery. Thanks for following along.
John
[url=https://forums.woodnet.net/showthread.php?tid=7325245][/url]