I'm making two panel cabinet doors. Got all the pieces made and (mostly) sanded. Yesterday I decided to try to glue them up. I got one done, but not without a fair amount of angst and a flurry of unkind utterances in the direction of the wood, tools and the universe in general.
I spent my commute to work this morning musing on what I might have done differently.
As per suggestions here, I made the panel a little small, and didn't apply any glue to hold it in. I put one of the stiles in the bench vise and built the rest of the door up from there. Thus the door was essentially on its side during the process. Like so:
I had three problems.
- Squaring up: Once I got the last piece on (the top piece in this orientation) I put a framing square to one corner. It was off. No surprise there, but adjusting it (with a rubber mallet) seemed more problematic than I had expected. Having to tap it, then check, then tap, then check, then ... was tedious, especially when I needed to tap one of the rails *outward*.
- Which brings me to the second problem. I have two black rubber mallets. I used the small one mostly; 8 oz., I think. Although I used a piece of scrap against the inside edge of the rail to give me a bigger target to hit, I still managed to put a black scuff mark on the panel. Luckily, the mark sanded out before I went through what I have learned is a very thin veneer, but I'd like to avoid that on the next one.
- In the end the worst problem was that there was a slight gap between the rails and stiles, a gap that wasn't there when I dry fit the pieces. I doubt that anyone will notice this in the finished location (a few inches off the floor), but it disappoints me and I'd like to learn from whatever mistake I made.
Here is my own assessment of my mistakes and ideas for improvement.
- I'm planning to make a jig of sorts, even though I have only one more door to glue up. I would assemble the door laying down on the bench instead of vertically. I'd make a (shallow) U-shaped jig that would hold the first stile snugly in position on the back of my bench. The side pieces of the jig would be just long enough to act as "stops" for the rails. I'd then make corner marks on the bench top itself (on painter's tape). I'm hoping that such marks will show me exactly where the corners of the finished piece should end up when it is square, rather than having to reapply the framing square (or worse, remeasure the diagonals) after each mallet blow.
- To avoid scuff marks, I figure to use a thicker block with some sort of thin material under it to protect the face of the panel.
- This one has me perplexed. The splines I used in the joints fit pretty tightly even when dry, but I'm pretty sure that gap wasn't there in the dry-fit. Is it possible that the splines (or the wood in the grooves) swelled a little from the moisture in the glue? (Titebond). If so, maybe I should shave down the splines just a bit. I should add that I was taught in High School (back when some of the trees this lumber came from from were young) to wipe off excess glue that squeezes out with a very wet rag, which I did. Maybe yet more moisture to add into the equation?
As always, thanks in advance.