Walnut doors with stained glass inserts -COMPLETED

Darren Wright said:

Can always send me your files if you need any of the pro features ran on them.

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Darren thanks for the offer. I might take you up on it some day but, at this point, I don't even know what the Pro features are and whether or not I will want to make use of them.

Frank Pellow said:

Darren thanks for the offer. I might take you up on it some day but, at this point, I don't even know what the Pro features are and whether or not I will want to make use of them.

Click to expand...

Mostly it has enhancements for printing and printing out material lists. Can also export autocad files if you need them for having scaled drawings in your wood/metal projects.

Descriptions are on this page: http://www.dfly.com/editions.html

Week Ending November 11th:

I spent about 10 hours working on the doors this week, but it is the stage of the project where there is not a lot of progress to show.

Walnut plugs were glued into all the screw holes then trimmed using my very impressive Veritas flush cut saw.



As with most of my Veritas tools, the does exactly what it is intended to do, it does the job well, and is a joy to use.

Both doors were trimmed on all four sides using my Festool track saw:



Next followed at least two hours of sanding with grits 80, then 120, then 150, the 180, then 220, Most of this sanding was done with a Festool Rotex sander, but a Festool Linear sander, and even hand sanding was employed as well:



Finally, I applied a coat of tung oil sealer, followed a day later by a coat of 2 parts tung oil mixed with one part sealer:

Week ending November 18th:

I was too busy this week to spend much time on the new doors. Actually, I spent no time at all on the doors themselves, but I did complete the installation and sanding of the trim around the doorway. The trim in front of the kitchen tiles was not a perfect fit in a couple of places, but I managed to make it look OK by inserting custom-made shims:



On all the doorframe trim, I used two different sanders as well as some hand sanding. With all, I used a series of grits: 80, then, 120, then, 150, then 180, then 220:

Week ending November 25th:

This was another week in which I made very little progress on the doors between the kitchen and the dining room. I’ve now got to move fast if I am going to meet my goal of completion by the end of November. I did put a coat of sealer and one coat of tung oil on the door frame trim. I also got my Carey Mortising Template set up (after much searching for the parts which had become separated) and used to install one of the two doors.

Template on door:

Template on door frame:

Door installed:

Walnut doors with stained galss inserts -COMPLETED

Week Ending December 2nd:

I had wanted to complete the kitchen to dining room doors by the end of November and I almost made it. In fact, I completed them this afternoon –which is two days late. Here are two photos of the completed doors, one taken from each room:



I was slowed down because of three separate mistakes. The first of these was that I must have been dozing when I cut the mortises for the hinges on one of the doors, because I cut then into the trim and not into the jamb.



It took considerable time to custom cut little pieces to glue into the holes, glue them into place, sand, and re-finish the trim piece:


I noticed the second problem as soon as I hung the second door. The gap between the doors was between 12 and 13 millimetres whereas the gap between the two sets of door that I made last year is only 3 to 4 millimetres. I solved this by temporarily removing one of the doors and inserting a lip along one edge. This can been seen in the completed picture taken from the Kitchen side.

Thursday night when I was attempting to re-hang the doors, I encountered a BIG problem. I had installed the door stops on the door jamb about 3 millimetres to close to the doors. I tried removing this with a cabinet scrapper, with a chisel, and with sandpaper. But, this was taking far too long:



So, I decided to remove the stop strips. They were only “tack” glued and were mainly held in place with screws covered by wood plugs. One problem was that I had no more walnut of sufficient length, so I decided to attempt to remove the stop strips very carefully so that they could be reused. I f
first carved out the wooden plugs:



Any doubt that I had about how completely the plugs filled the holes and adhered to the adjacent wood in the jambs and lentil was soon dispelled. It took me a little over two hours to carve out the 13 plugs.T

he utility of Robertson screws was proven yet again. I had used 1 inch #6 screws and, once the plugs were mostly removed it was easy to extract the screws.



Once that was done, the strips came off quickly with the gentle prying of a chisel:

All that effort really shows. Doors turned out great.

Those doors are amazing, and just in time for Christmas.

The doors are elegant Frank. Fantastic job

On a side not it sure makes me feel a little better about myself when someone of your caliber makes (and admits to) making mistakes

Thanks Bob, Jeb, and Mohammad.

Bob, I am sure that I make as many mistakes on my projects as I ever did. The good thing that I find now is that I have sufficient insight, experience, and tools to recognize my mistakes and to deal with them. I no longer dread making mistakes and that means that I can tackle more things (and that doesn't only apply to woodworking).

Beautiful end product, Frank. Thanks for sharing the photos and the narrative. I've often said the true mark of a craftsman is how well he handles his mistakes.

Those came out teriffic Frank. What a wonderful holiday gift to yourselves.