Davids Kitchen Update 6, made lots of doors (w/20 pics!)

Hello everyone,
In my last post I had milled up enough rail and stile stock to make 21 doors,
http://www.federatedtool.com/david/img/poplarstickdone.jpg
I don't have any overall great plan on how this kitchen gets built, each step relies on the previous one. All I really started with was the outside dimensions of the spaces the cabinets need to fill.
For making the doors and drawer fronts, I placed painters tape on the boxes and marked out the overlay for doors and drawers,
http://www.federatedtool.com/david/img/tapecupboards.jpg
The hinges are for 3/4" overlay, so that is how far I marked back on all sides, except for a 1/2" overlay where doors meet on a common stile.
Once I had recorded these measurements, I made a cut list from there,
http://www.federatedtool.com/david/img/kbdoorcutlist.jpg
All stiles are the full length. Rails are 4" less on all doors and drawer fronts. Side panels rails are 3-1/4" less to account for the narrow stiles that meet up with the face frames. This is fairly easy math as my rail and stile stock is 2-7/16", 7/16" being the tennon length on the rails. Panels are 1/16" less than the rails and 4-1/16 less than the stiles. The drawer stiles are only 1-7/16", so those panels are only 2-1/16 less than there stiles. It is marginally more complicated than that, but not much.
I cut up two and one half sheets of 1/2" MDF for the 21 panels,
http://www.federatedtool.com/david/img/mdfcutup.jpg
I installed my 15 flat panel raised panel bit in my router table,
http://www.federatedtool.com/david/img/panelbitinstall.jpg
I wasn't getting the size of tongue I wanted, so I removed the bearing to allow a greater depth of cut.
When I was running narrow boards, I used a second piece of MDF behind it to be sure everything wound run straight,
http://www.federatedtool.com/david/img/raisemdfpanel.jpg
You can see here almost all the panels run,
http://www.federatedtool.com/david/img/raisemdfpanel2.jpg
I then primed both sides of the panels with a shellac based primer,
http://www.federatedtool.com/david/img/mdfpanelsprimed.jpg
A light sanding removed all the fuzzies from the panel raising. It was much easier to sand the profile before the doors got glued up.
Not the best pic, but you can see the 84 parts cut up on the jointer that are the rails and stiles for the 21 doors,
http://www.federatedtool.com/david/img/84partscut.jpg
Here is a shot of me setting up for the cope cut on the end of the rails,
http://www.federatedtool.com/david/img/copesetup.jpg
This is pretty idiot proof, I align the top cutters lower edge with the lower edge of the cut profile.
Next I make sure the cutters bearing is flush with both fence faces,
http://www.federatedtool.com/david/img/copesetup2.jpg
When the straight edge is slid back and fourth, the bearing should roll, but the strait edge should not rock between fence faces (all three are in line).
Making a cope cut,
http://www.federatedtool.com/david/img/makingkbcopecut.jpg
You know when you have the cope bit at the correct height when there is only the smallest wisp of material left on the top and/or bottom of the cope cut (see arrows),
http://www.federatedtool.com/david/img/kbcopecut.jpg
When you are coping the rail ends and have a square back edge, you can use any board to back it up to prevent tearout. When the profile edge is at the back to need to first run your backer board through the cope bit to run a profile on it,
http://www.federatedtool.com/david/img/kbcopebackerboard.jpg
Now the profile fits into your backer board and there will be no tear out,
http://www.federatedtool.com/david/img/kbcopebackboard2.jpg
http://www.federatedtool.com/david/img/kbcopecut2.jpg
Now the fun begins, I can start gluing up doors,
http://www.federatedtool.com/david/img/kbdoorglueup.jpg
I place a stile in my bench vise and drop both the rails and the panel into it. I pop on the top rail and do a test fit. I remove the rail, add glue, flip and repeat.
Next over to the clamps, align everything with the fine adjustment tool (small brass with wooden face hammer) and tighten the clamps,
http://www.federatedtool.com/david/img/kbdoorglueup2.jpg
I was only able to glue up 11 doors tonight as I ran out of clamps and time,
http://www.federatedtool.com/david/img/kb11doors.jpg
I hope to get a few hours in the next few days to glue up the other 10 doors...
Thanks for looking,
David.
Every Neighbourhood has one, in Mine I'm Him.
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"David F. Eisan" posted his door making adventures

I love this last picture.
It looks like a woodshop version of the "March of the Penguins".
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I told TW that and she laughed!
Thanks,
David.
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Proof that one can never have enough clamps.
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The last thing I thought of as I left work last night was, hmmm, I wonder if I should take home more clamps....
Looks like I should have.
Thanks,
David.
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David F. Eisan wrote:

Nice work david. It's always nice to see what other people are up to.
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David-- Great work! Two questions... When you raise all those mdf panels, does the bit wear out? How do you apply the primer--spray, brush or roller?
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The bit is a Delta branded Jesada bit and I have used it for many many doors. It has not shown any sign of wear yet. If and when it does, I will just get it sharpened.
The primer was rolled on the back and brushed on the front. This is a budget kitchen make over and I will be brushing, rolling the final coats of paints as well.
Maybe some day at my next house I will set up a spray booth....
Thanks,
David.
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David-- Great work! Two questions... When you raise all those mdf panels, does the bit wear out? How do you apply the primer--spray, brush or roller?
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