11-09-2016, 09:16 PM
Here's a link to Part 1. OK, now I need to join those nice parts together. I was not able to find a sash bit even close to the profile of the existing door, but I did find a molding bit from Grizzly that is almost perfect. The cope and bead radii are almost exactly the same, which allows it to be used as a cope and stick bit to join the mullions and muntins to the frame and to each other, as shown in this sample I made:
![[Image: JfU7-0E-w5jiebmWdvnAEGfLIq-3AsBBzVLym5yQ...38-h628-no]](https://lh3.googleusercontent.com/JfU7-0E-w5jiebmWdvnAEGfLIq-3AsBBzVLym5yQKKh56WYzJTWT_Nnn-hah4eHb9pbKKxiJNd2rK0gyUYgkiv1hULdxu8FpjF1iZpXWmBMlo3zaZT7ut-NT0R4Gv3HUZg2q--kaJIWSBYCdLHuT2a9hr23wbodpm0idNBkbhcBc6FvA0b0dbrkQwuawshJb2gFcIcCJKECr9yf2jV1rrKzfGOTd7E4_F5xEHjOqsbE4oMfuYC228TugysddYUNuLCP_r-Q0ly0XKEn-1TxrUkUmd6nqMDTCWwl75d-xCa3AXr97Uy6lVTbfBNMvUodTuEuSOhvFB7XolneC98XtaHgvmkcz702F3NFqXSiM3xieBq7E8cZdBvX8YaUv-_XwjGqm5_5XoO3BpcHrSi-QRxrc7IR6ix1x9PU9qh6ZpyXb_ZgRDiNwJcJmdLpKjQN3a3jQJbkFkR9a6SEh3FhtjQgQ9c2hlNflJoIOAzI_NyKky12CaNthnbBX15J_vvtaIrC_kvBmqDlNVDTn5VrzU4BEqVSFKb4gCVQYDH8jmfOBFioyvL0rqHCpa7a2d6EQq-RQmN8hovvqSuxKhquqskSMy4z2xKq0TZOZ-BzuHhY9m_ZzmA=w838-h628-no)
More on that later. First I need to join the stiles to the rails. The first step in that process was to mold the inner edges of those parts. Off to the router table:
![[Image: tQjFkZsGlXdsePsrJkVBIWYCrlfKdvs4NtseySf5...38-h628-no]](https://lh3.googleusercontent.com/tQjFkZsGlXdsePsrJkVBIWYCrlfKdvs4NtseySf5DfluxDVTjP9KFdgNdb6tSpzerY-XTI9Auyr0T9W3rGLEhYz10X6IWmQh4WPg7losoCtXz9rNfCOtp53gqq2oOCBbxP_ZJ0pJ1oZ7blXC_2HY-nt-9JTvwRhJJnB13vpuUVx_iDmt9Qk-TB7r9lbZSjQJjWPjaankxsHGeUcib42QV8PRtkYb_l9w6Rn02JBZ3WbQT9bg4_76rRSYulF-2yAIry4A8Mbz-w_phNJBmj6k71ApDecvRg8rUDyHiC2LJMmPM0sSEcYMsQTUpMcO10OOvp0y5POR7gcxz1y33kFqyIu7FBOJRFnLXTvmt1vSCWxSQSJ0HccMzDcWLjtPoeiBvWtXGxeyBI9y6JlCVHY7L0Qc3H_B21licUtRqnoS2wbSts6C7QjMSu-WdY2grvOF2z-xNdK64M9gqV317nrozNVXOjqq9c0WKtOJ-ECQ-5eH9Kt4ViHcv1EqPMlSuIr8tdpt0DRsfaIrZvI-PlHFCxbExZRBnGuE_rYrxl-RMbOAo4hguswhoe-Ss8X97w1JYbGvTE6-Cs1xgBTYrBDS_YXOr56dowjubE5rVhfiqrblZHVluA=w838-h628-no)
Then I cut a rabbet for the glass on the opposite side using two passes on the table saw:
![[Image: -E4MV8gBC_pOdFnHeJbB8yMtTkB7wp4-lc4VLvdC...38-h628-no]](https://lh3.googleusercontent.com/-E4MV8gBC_pOdFnHeJbB8yMtTkB7wp4-lc4VLvdC6SyJES0v1eSTCqqNBfUhuqOLLNCY-0n-DCFAVzjtJiyHz7OfLw1K7QDtkBwEC-AkEh2ricxFbtr592RSxHrWmL9XzCbqEw4Er5RVLO1Sgx4cMXOIfhYDNXPmYRbNSscgkchfc65ZYdALiGIEyvMRCsOEoTNhASKUCygbScY8cXbrAWL7GHEwBXdPAwBdOWbcS-N1ho_YEQtoddY-JtQhBJuECaPSXR8uUjDShyEAbU-KJEeC1OYFSHbo5Agzi0oKFQP0LGBCJiH7xmRcjyKCj6eHnpgwzW3khgSu9OJF3X-nj20DnZwqSF4BccfKvMThLlheQnwK-wIWqopCDbpcemcBSsxVv2T9ywdQO8BhRjbMP2rQJEhAbg5UOXWe0MHROYEDcSHAWV2YxejW2_W422JJlkLd2P8Lgl4ykBAdsTol85HLBoGt9VK0TPQxpuGhCGlmYxQp3ywisMf6aeza9ZcDzi4ylHMwlsalpWO9TJJprFk6Hs0NMJxav-0uJlkFnyq0Q4psh5XcPAw206jbkZeioCcA5_yRZ_YOQGIwoJ4DmbQiZukZh3bu8_-D02s0IpNklTecug=w838-h628-no)
To join the stiles and rails I used jack miters. To make them you make 45° cuts where the stiles and rails meet, then you remove the waste on the stiles, then cut your joinery. I began by cutting the stiles to rough length and the rails to final length. Cutting the miters on the ends of the rails was easy on my RAS:
![[Image: LCjqzOQ3WlnA45RFBODDIjWXsROYHfngHNjwDE-8...38-h628-no]](https://lh3.googleusercontent.com/LCjqzOQ3WlnA45RFBODDIjWXsROYHfngHNjwDE-899niGLWqEBBlXSRnclGPPG94ES55xXZJJyGWmzaTVGoJmfrDf0yEzyg8Dh-QL2OgZk4HSPSmWEQaBPmmPidgJcJIB460U9iesNQEXFxZxd8QYAuu2hFSSkOqnha0x5AiIAgvLwqBC7IvFOm1MNHGWktDOxogaBaj7MIgy3dAWfPHxDHef8hnT9qlAkN9RTETVMmB32p7kvq6FE_eBqDCVqTT35IYzV6jeYzYopyIXtFWARY_-pP3fkYu7W0Gwq769Sc2w-q9N_ucoLY4hnaEybyQhUDDGtKW6FW7OE_AAgr_UYjxhl_WMfmOxjOT2HpglYrqi3djfkHaAoJKgzmcg7ZSE3zxfs9IScQSrkIeOEPZoDxqSNY2R8BRcxxgnmU8jjHeOTuJal8jwzDN4EyFdZKjYTGsCBVN_moAYy0g-xiHBCFD7gc5_TCDTgoxl-QTWZXA97rTjMRusOioY0NLqj30iDTZXqoq-A9wPipuNadhPoTeo2Ju9XiyIMNJ0V8Piz-kl8Bo5-yLcKmgiNBLG34EGKfkr8VS7oXvkUz_BfqMbeoVYxIZWeiW3d8kjup_M_-miGrzWA=w838-h628-no)
On the stiles, however, I used a different approach. I made a little 45° saddle to fit over the stiles, clamped it at the miter mark, and used a handsaw to make the cut:
![[Image: -uCc9JXZVdZ9BX36ZpEn77JYA2IioP0PQ4nV9kN_...38-h628-no]](https://lh3.googleusercontent.com/-uCc9JXZVdZ9BX36ZpEn77JYA2IioP0PQ4nV9kN_vNTtt9zFh1WnlbTLt2N8Rlv-YmiHhGLyFlKKp0ujDMuX-uOGBc7_eQlT9QS0AcQsqg-olrk0HT2LUR6DQOztWaoQ2r-DfNF9pVwMHWdiURfTtBeuVZzVcXaKR7XUiQikWMyTbVTLqQQDKKt1QTqsQCst57N89gLr8dV0vRmk2K8CGc_Y8JHlhKpGOp1awYUw_uuX7tUQ7t0HUdxkGI-5B_PX4bbKsEZPUehJAOkwDBGq33DHXtxOk5P3di4VE3evxPz-TBad_CrIziAyVHotMqVf_yhhxph-Wd6Tc2D0XSE5E20COkPzLAzvXkbmNS1sA5qpC-rtqUtrod4H9Y4AgtijAzZhRbKntOQCQU8mDYaIQdFV2aZLHW3WzhQ6nUftBCCuZ8Ejfi199WE8UIZo666SfK67bu47pRq_rxLLciuvJyaA4uMRBt2mLwkBmNYT1hRlh3Gy9qpwSdwKHZ_B4-AHs1RodPjtnaLoDuwFBZq3DokZWcm2bmiAit0PhKyogxmsQOrjowKExuMrYO8TTqfOMM4FiFMNrKH-GwhN9LPLccKTM1F7FiuJqNhQJXgM6wF6VWu4KQ=w838-h628-no)
Then I cut away the molded edge on the waste side using the band saw to remove most of it, then a piloted router bit, hand plane blade, and bullnose plane to get the rest.
![[Image: fm3G7TqAHjV72f6gRyGWsA376CvsNZG3-6kFoKG1...38-h628-no]](https://lh3.googleusercontent.com/fm3G7TqAHjV72f6gRyGWsA376CvsNZG3-6kFoKG1LmnFjKLOjNB5smjkLGSwnVqxHv5KbdyzmtVg74b2etUtCPsY9uOydbMS-A1Hy2BF0G6GjbloPQlTC5kzr_rNSeqMH_2V3d1xkaTXOhOhtDCCO1rgarKP67vHeiSwltE4F1WuIUR2wO4ZwOCQROvTe4phlByDFVRZz5qo09DjqBSkm43kf-4ixnAz1f07u9gAKpRFyKcRlm11GDTSnUAxZCWRExbRoB1Mq-fHtewB0uHWTNa5cQ3O2U_Smd4x2PFSq8Efp1sK2-wjRH8-5AFVnqeXCwBM2gUpy5e5Ca3Q-b_foKl9ZY_dqkm5UvRiI141GnZlIo_uUB-NlldGs2ds2T2qWc65Xnnx000o-KUqZIVgKg-6ArurYRzIlWBLoRs5hewYNxuvRVU5YdrjFbtQD45E0qXKJZvWI9GrEifHC557ELCcACClu1DXX4B5jMwY_Gx-8I-RCTiXHw_9tvAoyblALt83NQquOuSf4F4lFkBhY4Uy6dxqCpTo3JwBLXkrWuUN-pa95BBNVCXvrXG-jkK4F3POVv_8CD8eoz7uXchTiT0G8Y7yYlx3nOPd80q2GcawhRNOrg=w838-h628-no)
OK, now I needed to join the stiles and rails together. I've used my horizontal router mortiser to cut 1/2" mortises on some 1-3/8" thick passage doors in the past, but I didn't feel that was thick enough for these 1-3/4" doors, nor could I route as deep as I wanted. Fortunately, my the MiniMax J/P I bought last year came with a horizontal mortiser attachment, so I used that. Some trials earlier this year proved that center cutting, 3 flute spiral end mills work better in it than the Amana mortiser bit I tried, plus they are cheaper. Here's the 5/8" end mill I used:
![[Image: wdQtuWJTVNKga9EMDuvc3gEILxgDP8eVRM0c7UfC...38-h628-no]](https://lh3.googleusercontent.com/wdQtuWJTVNKga9EMDuvc3gEILxgDP8eVRM0c7UfCveE1njDK1cjiUZQpoh5H_r2lRAOGF38EIoWO-8DUmM5nVChBDE-rFJL904HfrH2f8MAj7or5paG6JXFdxHfAvo24fxr3BagjYd6n16xg7yhlOqag49u_38YZlO16HgcMySOwmcJrNnruUI4QPxNyCQ7_KvqmO0YIVhmX2Tc2vMrDi4Tw4tZh1WcnUj6HHe8wlsSAF4JQsxIzJxkl7XzdBuaJqUdkMu9-XKDz4GSTvCGMeXvsRx4VBhJn7YlEorTnW8Rl-w1CYXMxWhoNCDc-uTmIJeB2NVnxLC0Y6AkWMTdB_rqkuFjEr1CGug27brg-AzICT6D9qORZ3SzEX45F9ijoKeRSgeulso-yNg2cfP-GnWqhGsYK6Qomw7G02tTACQEnK-5giWNMd6GNfor30cXX1xlr7jeLZ1gXGtnDEbAPCliaUrgJdHB0GLO-hc_BNGZgR8JogHmd9n1Wt9oSIPtlOYJQI40Rj9Nsb8fHKTqXenwc3Sg-lvL8oJuNezhIqeSyg_okq_LXOFjTb_Y4G1KE5W5tlZhIVKwWLg3LPllY7tYWB9argrO8P02SUDBzPmN6Ay7PrQ=w838-h628-no)
Here's one of the rails being mortised:
![[Image: EysXHonJH-4BdOH894tunIH97YwNgYgGt1RTyT7i...38-h628-no]](https://lh3.googleusercontent.com/EysXHonJH-4BdOH894tunIH97YwNgYgGt1RTyT7iuC8O6ZF1jiE8aFhYWowsYN74AalcLgj5zo7y76PT52RsoD7y3E9iUkVxqzREZR3TkQfQW1g-289ExDUE8QAn768izrU3PGb5XuBhIhvtCEjO3JaEVdY8OH2iGVbjVV5u5sm6rqSUHBfJmTGrbQTCmo06EtWEw2SAHKis43KzN9EBI23RBtxLU8c6qTtANHYsWq2VwrJ1bLTb4jmAb5iNEc_-3RXxsWx27I8evezt3KXOLvCaAsRmnXPt2KL8cd84jU6OwXCcnBy72Zdb5s_hsmflJ0QW95rc_1d-lrd_AOrNdcd5uNndvuNkwu9ROqLexKYvGR5kpbdyqjlNQfEiRilODMFcDW2-rG4yuEXc-I3joSX4O8Zmz4V8VRxlQ4av9piMJlQGfOL2s1Dla5arJN94944SBBwAxmP-UgnImD9RnRN-UStrGrEqPmhCvFdyo30P8LL88G757vYp5pEuAezRYNPyhSb6gxZQN3gMJ8OsM-rGRx59nMxTwVJeGXZYySr0dBuK7Ayf53_K4QkS2vtcAXZd3K8Dcq0Zo0tG_xK0qBLXbtDqtJ2ApSezX9Thx2LE5VjPDg=w838-h628-no)
And a stile:
![[Image: mKmynQWYUOGtznFUp3faqv3dtHHjj9s4mJ93XXS9...38-h628-no]](https://lh3.googleusercontent.com/mKmynQWYUOGtznFUp3faqv3dtHHjj9s4mJ93XXS9xS-LZNHXSgZV_sBQ0tGzDdoPXewRlRQ8oe8TnyBZTGmjl7ypL7nAYn3FzQRoB8EWAHYV8JDJL2uiU-KWtF5qcT9w7814ASzh4dc4x7yHUajonYmfMxq7TI1rggUHt9hAmpPLkxpjxHvQ5b0GxuGQvy7JT1J8NXPqs8m9eXss5z5U8OJ_kXkzb-Jgix3Z0qQdb4oOfPSh8POkbY_ObOxQc-UzYZXHGcMLAjQiMRfB8uYsM7K3B5q7VJ-QWZ7qWoaSJwJe5mqqRM-iNhENHQCCnZz8a3Laf1Mhibg0VSbOFGJ2uwvjDKQGltIAE-OHym-bpREn0L-mMh0zNZ2pEWuYMtykuCSw7HqsCIpGIgXw3n_-YhPVN8UazIBMBymmsEVh-9lYWLhmAPwowGvaQPZaBK8p_61JTqmYbK3gR3gS3j55MFy2eunRgp9ew6TYkvcbz_RV6301E5IPQrFV5WrJ1_vXALNIQpFHSHRdfFuuy7VjbqXN10jw89qNVVFTSzLlrMakRXd3oEhDMxGtmwV7zsYMjQwVi08cgOTTyS3RqL1ipHxT3vMBiIOvTR39-jClo2QYqOvuNg=w838-h628-no)
I made the mortises 3" wide and as deep as I could go with this bit, 2-3/4". Here's a close up of a mortise, very smooth:
![[Image: ukbc6yArLo2Wb7eUaqd23LO8tvJrSxrOT6suDtvX...38-h628-no]](https://lh3.googleusercontent.com/ukbc6yArLo2Wb7eUaqd23LO8tvJrSxrOT6suDtvXzq9b7Pzg9-fJVQNCYMKLBfmlGSeqQ3L1R6s3QaiphQcXl1ym_L9Gh02hOnYuitfU-NlGDPfqOCrl0EaCaP8qrM_MCs5cqhD7KNSu1c0VVoMKYlOiXeAY00NdyfcQKYvcpmU95Bt7AfI0K8RScAlH82xqOKSoWTXTnrEy1t96Yk-5JgveupGKT8AJ587JhZ-CnP48D3taCygPTdE7ohG_s2X8pIQKLr2S8KH_H7k8XfBxRKFIDBcOgCvw-cB22Z0INQ6SlcYj8oYK2WPcYmqSEKBKU81Qj-L_OnubM8TAYjBbP7mjeZtF6IGP6CTX49tgl2LRziWF_n1HlrjXi_VOWV2LJfLsAC3RnIXevl_B-uwS7z-3a0WOP3EGF47014hy0bSrC9I1CZG98gHfD6HElCw0i22jiI5IpZkHDUR1ljHKUaVlqm12pTUoXHtogijK5qNK3B4KYRFc1yEMpbkjRtfW3oBxwiycYgZo4C65POtnWmVyXFd8bamahK7dP5vJXvJnNNEZaWjiD00V-VzIfxFS6OezYrLQKb_dpGINIhwlmCENNOdD9kTH6NGXFQBZcjeJRFNb7A=w838-h628-no)
I made the tenons out of white ash. These are the largest loose tenons I've ever made.
![[Image: jS8ltFM70H2K2I3_TqoUZNTMCp4pmA48ejfACmyR...38-h628-no]](https://lh3.googleusercontent.com/jS8ltFM70H2K2I3_TqoUZNTMCp4pmA48ejfACmyRZCdiznFo-YghYT_6uJpQxU5GCU5TVk2YxhlsIEtSbmwGZ2LD9C2ubpvLJPPUNn5ciOrql0rtmzci6hDRsuPwG97mM5lGcGCPzrO32jdCFEeR7xt9OieqwSwfOXGfjg2HyVmE8keUJT4FNM6bA_bXZqaXEN4ixMuhVf7tWQ_Ga754jHyAcevLfJ_No_XnA-oFtMYieiwuoYS9F7ceFSxXev14bkQVd8mGTLSGlNQTJOScZU9PMfxsYjN9a7HApTK2XQQipHisAQGhzi8mcuk6TLZE1d543EO6B3qdW3NBTsZmAIRkg_pIG7tNrZjZAKDsLxVBArUfL7LSgEq0SUf6gVhXfkQYdt_aN31Jw7oq4rGeka7nmeCPuWati6unYMdfP4P7IDhqzF7RjPbiveDVPY5dsZRvTcZTlyQMgAbGmyNkilLBNkNEuUKwfm4x0kXxe51jKyw9UXchjbAsy6p8Ri4U7irQ92_OtxWTMAzbHMireb6iQ7j0RBkvc5TSaQ6xZVpExW0TIR2aFTaZdIwg-PQvjR6Qj3uPZ9IznwAWSHbc322n0Fw-sOME75wDIPHdsAtmNc4pGA=w838-h628-no)
Here's the door put together loose:
![[Image: iEgBMvSDCamqrfuFApM7HPAgOv7OuAQES2bu5CJT...38-h628-no]](https://lh3.googleusercontent.com/iEgBMvSDCamqrfuFApM7HPAgOv7OuAQES2bu5CJTC42zgTX-wo-os0HetE9PcZ0oLXy_nTwGPT7D5S9qvCisxc78w0KqTy5d5P8eijq-qX_ub4fmzBSk0AtTdkfjVth5lyxTfcwUVHObygWkov0-RMdHO8MTSBq74GrYfsXBvC3MVdaeZoERImH4e1Xui_0YXxPbFh6AEXHmK6x4Ryz7D9Shwpk6BzUmU0RB_mfzv9vLEL2iJKQMzFF1XuYFFmWNeH_Gbd01v9RrM80A-QYSMhUVUK2-l5D1IHwalypiFAPYtKXNu2Gsete7TC1HfwIiG3SVgvrdBnz2UNgb-KnYT4EOjdZke1ROYNlBi5qK8_V8V5pBHRhGO5KfK15J6ZnQc-1qRzvyCY_lZTlUUq9Zk0yKNDdEDQDlQLENk8kmDGXlLvKayZfk6PVDxDyQZVLn6gF70j4FWlIwa1iqO-JQSOHjkKPVBBuJ58iTlR_bHFP-M8deMGL6GSlPmoaBg9-rppKO4jyRM0dvTzBNOcVP8VOBl-aD2YWoFkKZ-_-SRigjYEpRAAGH1prd_CFoPAh56EYsPfaWh77gWAM7QIybR1IIaTrShSOi8WN1D3dSGrIHFMeMig=w838-h628-no)
And a close up of one of the joints:
![[Image: sbCnKHc3YK0Q_lVT7eRvOPAzS0Ao0OZA5oJi4Vcb...38-h628-no]](https://lh3.googleusercontent.com/sbCnKHc3YK0Q_lVT7eRvOPAzS0Ao0OZA5oJi4VcbHVZwl5KfajmUgM2VoBhkmf27_CC-flZhdL0wmBzXzUvu0GjnCu2t2iZISrIc5T39KMllcnp65If6s4nDgXv82vXi4KzJ0TKJM1co6KYFKBuqDYoDMVkQZlD4qJWv3aEcH2MvJN4R22brnC-dC2eY76nIV2xwDW059inAms-5pN-vOcjrhG-Oct_OPwzPhOEascFw7sSJfZA2PiVh2OX_dX1gU9ZQo8z6oVVRrXZ2RM0buA_ZHA7MaVfSUsRtF3wai6Nq1q--GsUOZWNf2FhKA67Yj5TDWYwcQAZKqsjL9ewxauG6q2Uxe2yF44e20AzdjUQRQtYx-uajUbOY7YrH1h6BjmPC_hCcbd7Gf4ryB7AjHvRz_io0v-36I8T2yCHxr6fah32g9YfDJZMF-9iST8ERNOxU-ELgo1gB32ycu3LBxravCzGscBZ4vCcdCAwzNZ0Wla6Xwyl5IWalRNUNZJFoyeJzDd0l8spN5FF4aihKArvkxrQZ-p9knxtS8RBXQLMX5bgv9RBJO4kvB4USq2ZlDippBR4CdafQJfW8OiZ4vgPQCsFz7XASnBeEhJOF6wegLVim7A=w838-h628-no)
So far so good. Next up, the mullions and muntins. Thanks for following along.
John
More on that later. First I need to join the stiles to the rails. The first step in that process was to mold the inner edges of those parts. Off to the router table:
Then I cut a rabbet for the glass on the opposite side using two passes on the table saw:
To join the stiles and rails I used jack miters. To make them you make 45° cuts where the stiles and rails meet, then you remove the waste on the stiles, then cut your joinery. I began by cutting the stiles to rough length and the rails to final length. Cutting the miters on the ends of the rails was easy on my RAS:
On the stiles, however, I used a different approach. I made a little 45° saddle to fit over the stiles, clamped it at the miter mark, and used a handsaw to make the cut:
Then I cut away the molded edge on the waste side using the band saw to remove most of it, then a piloted router bit, hand plane blade, and bullnose plane to get the rest.
OK, now I needed to join the stiles and rails together. I've used my horizontal router mortiser to cut 1/2" mortises on some 1-3/8" thick passage doors in the past, but I didn't feel that was thick enough for these 1-3/4" doors, nor could I route as deep as I wanted. Fortunately, my the MiniMax J/P I bought last year came with a horizontal mortiser attachment, so I used that. Some trials earlier this year proved that center cutting, 3 flute spiral end mills work better in it than the Amana mortiser bit I tried, plus they are cheaper. Here's the 5/8" end mill I used:
Here's one of the rails being mortised:
And a stile:
I made the mortises 3" wide and as deep as I could go with this bit, 2-3/4". Here's a close up of a mortise, very smooth:
I made the tenons out of white ash. These are the largest loose tenons I've ever made.
Here's the door put together loose:
And a close up of one of the joints:
So far so good. Next up, the mullions and muntins. Thanks for following along.
John