Door Mode

[Masonsailor]

The boss says the weekend is over so it’s back to work. This is a phase of the project that is going to get tedious by the end but has to be done. The doors in this house are the standard raised panel doors that are pressed out of some material to look wood like. We will be replacing them all (18) with new doors made of Sapele. I am driving over to the coast tomorrow to pick up 700 bd ft of it in 4/4. 100 bd ft is for Static LV, another friend is going in for an additional 100 bd ft. It looks like this project will use about 500 bd ft for the doors, jambs and molding. I will be laminating up 4/4 to give us 1 1/2” thick doors. The molding for the reeded glass interiors as well as a Zagarat design on top of the doors will be Wenge. In the past I have used a Shopsmith in horizontal drilling mode to fasten the rails and stiles with 3/4” dowels. This time I am contemplating picking up a Festool 700 domino tool for the job. Sapele is fairly hard stuff and drilling it is not going to be fun. It’s very similar to red oak in hardness. I am just not sure that dumping that much money into the domino tool is worth it. We are going to give Tectus hinges a go on this project for the first time. I have several friends who have switched over to them and rave about them. Having concealed and completely adjustable door hinges appeals to Ileene. They are pretty straight forward to install with the Shaper Origin and I ordered up one pair to do a mock up which went pretty well. 
Paul

[Gene Howe]

Following this project with a high level of enthusiastic interest.

[lew]

Watching this build!!!

[Danl]

1 hour ago, Gene Howe said:

Following this project with a high level of enthusiastic interest.

 

3 minutes ago, lew said:

Watching this build!!!

ditto,  In 2021 I replaced all of my interior doors.  I started with purchased slabs.  I know how much fun that was. I got a good work out from lifting and flipping during the finishing.

Danl

[Al B]

Waiting and watching this build with enthusiasm.

[Fred W. Hargis Jr]

That's almost 1 1/2 tons of wood!

[Masonsailor]

You were close to right on the money Fred. The trailer was just about maxed out. And it’s made to haul a Bobcat. I included a picture. That is minus 100 bd ft for my neighbor, so that is 600 bd ft in the picture. 
Paul

[Masonsailor]

And another 100 bd ft of that belongs to Static LV. Now the fun begins. 
Paul

[Fred W. Hargis Jr]

12' boards? Nice!

[Masonsailor]

14 footers. 

[Gene Howe]

Paul, if your doors will be standard 6' 8", 14 footers will just work. I'll bet you figured that, already.

[Masonsailor]

That is the plan Gene. We have come up against a problem with the Tectus hinges that may prove to be interesting. They require an 1 1/4” deep mortise in the jamb side which means a standard 3/4” jamb on the lockset side and an 1 1/2” thick jamb on the hinge side. That is going to reduce the door width by 3/4” which is not a good plan. The hinges are held in using two 1 1/4” wood screws. One solution is to use a standard 3/4” jamb, let the hinge protrude through the jamb and hog out the Jack stud a 1/4” or so with a forstner bit to give the needed clearance. I would probably have to resort to machine screws and t-nuts instead of wood screws for added support for the hinges. The other plan which is what they do in Europe is to remove the Jack stud and replace it with an 1 1/2” Sapele which serves as the jamb and the Jack stud. The latter method actually increases the door width. Not sure which method I want to use. I’m also not sure if the latter method violates the UBC. I’m not into remodeling and creating code violations. Mostly it can complicate insurance claims down the line. Will keep you all posted and am interested in opinions. 
Paul

[Cal]

Good that you are facing this dilemma at this stage, rather than after you've built the doors!

Assuming your jack stud is attached to a king stud there shouldn't be an issue with hogging out bit of it and simply using a longer screw to get a good hold into the king stud.  My 2 cents, all I got Paul

Had to find some info on those hinges and found this short video:

 

[Masonsailor]

Today was playing with the Shaper Origin and the Tectus hinges. It was quite a bit simpler than I was anticipating. The cut files were available on the SO site for the hinges so it was really just a matter of sizing it to the thickness of the doors which is 1 1/2”. I had to make a jig to support the SO but the cut files for that were also on the site. Tomorrow it’s time to start gluing up. 
Paul

 

[Masonsailor]

We have spent the day milling and gluing. The first two doors are glued up. Now I will let them cure for a few days and then mill them to size and make the two doors. She made a change to the “Zagarat” design on the top rail but I think we arrived at a good compromise. While the glue is curing I will do a test run on the inlay and see how it goes. 
Paul

[Masonsailor]

Back in the shop today. Got all the laminated pieces milled to thickness and some of the drywall removal in prep for installing the jamb. 
Paul

[Masonsailor]

Spent today getting all the jigs and SO stuff in place. It was mostly cutting stock to length and prepping the inlay for the Wenge. I had to develop my own SVG files for the SO as the ones they supply had a flaw. Next is inlaying the Wenge. We also prepped the jambs. 
Paul

[Masonsailor]

The Wenge inlay was more about making the jig to size the pieces. It turns out cutting small pieces of Wenge with a miter saw does not work at all. They just explode. So it all boiled down to using abrasives and the Shopsmith. The pieces get pretty small. Any way it worked well and fairly quickly. 
Paul

[kmealy]

Every big project deserves a new tool.  Perfect justifixation for a Domino.   Besides, dowel joints are weak joints once seasonal movement happens.  See R. Bruce Hoadley  https://www.finewoodworking.com/project-guides/joinery/the-dowel-joint

 

The Dowel Joint.pdf

[Danl]

I can't wait to see more.  thanks  

Danl