For some reason I want to make doors. Now I do need some doors, but
that's not the reason I want to make them. Since I'm a rookie, and
getting too old to acquire years of experience I want to jump right
in. But I don't want to jump right in with mahogany. I was thinking
of ripping good quality dimension lumber to about 1-7/8", gluing the
factory 1-1/2 sides together, and planing down to the right thickness
for rails and stiles. That way I won't cry too much when I throw
away a door I've made; that plus a rail or stile made that way would
be less likely to warp. At least that's my thinking.
Is this a dumb idea? You have a better idea?
I say go for it. That's the way I would do it for the first try. A few
suggestions: Take the time to carefully select the lumber for tight grain
and the closest grain pattern that you can find that looks like quarter sawn
(all the grain lines run perpendicular to the sides of the board). The best
router set for making doors that I've seen is the Freud. Are you planning to
use a router bit or some other method to fit the rails and stiles? I've been
thinking about making a few doors but haven't tried it yet.
"Robin" <RCG email@example.com> wrote in message
table and using a router. When I looked at the price of tables and realized,
given the time and trouble of mounting, and dismounting a router it meant
committing a router to the table I bought a used shaper. So now I have a 3 hp
shaper that can use router bits or up to 1-1/4 shaper bits for not a whole lot
more than the table-router combination. And as soon as I get 220v power
installed and a place to put it (probably late Spring) I'll be ready to go.
Then I looked at the prices of router bits. A router bit big enough for a door
costs hundreds of dollars, but I my shaper which came with a 2" high knife
holder. One can buy a set of knives for under $30. At that price they are not
carbide, but then I can sharpen then some myself. And I can afford more than
one profile. So my recommendation to you, based on nothing but conjecture on my
part, is to buy a used shaper, knife holder, and knives because it's cheaper in
the long run, and, hey, the shaper looks cooler in the shop than a router table.
Well, that certainly would seem the way to go, BUT I have a problem
with sources. I just moved from a white collar town (Washington, DC
area) that had multiple hardwood dealers to a blue collar town that
had one hardwood dealer whose phone is now disconnected. (I now live
near Hazleton in NE PA.) If I order thru the Internet poplar doesn't
cost that much less than mahogany when you consider shipping. I know
there are sawers within a two hundred miles that sell all kinds of
wood. My truck gets about 8 miles/gallon so I would have to buy more
wood than I have room for to justify the trip. So that leaves Lowe's
and HD. The thickest hardwood they sell is 3/4". I thought of gluing
two boards together face to face which gives wood bearly thick enough
for a door with no provisions for planing or sanding mismatched
joints. I thought about putting a thin piece of plywood in a poplar
sandwich, sort of veneered wood with the veneer on the inside. Then I
thought, I have the clamps to glue things edge to edge but I'm going
to need a jig or a veneer press to successfully glue such wide boards
together. Then I thought, This project is spiraling out of control.
That's when I came up with the idea of dimension lumber.
Gee, try Lewis Lumber in Picture Rocks, west on 80, north on 180 to
north (east?) on 405, from Hazelton shouldn't take you more than an
hour or so, and they have plenty of poplar pretty cheap, and kiln
dried. Tuba4/8/10 is in excess of 15% (or more) moisture and will
eventually disappoint you in an interior door application. DAMHIKT.
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