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Thread: Doug Fir Alaskan yellow cedar master build.

  1. #46
    Join Date
    Feb 2015
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    Beantown
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    With the panels prepped it was time to assemble all the doors. Being absalutely meticulous all the way through this project rushing nothing and taking all precautions has resulted in assembly being a piece of cake and zero fighting with my joints to close or mate properly. I would almost never be able to take this kind of time to do anything at work.

    I got pictures of me putting the panel into the one full size door. Itís a perfect pressure fit. No need to force anything but absalutely zero gaps between the slot and panel. Iíll admit I was not expecting this kind of perfection. Iím sure many will say why not but Iím a honest guy and I really figured some Co sessions would be made to perfection. Ok I did cut one haunch about 32nd to short. Other than that though everything is like 100% square beyond a 64th without evening sizing them yet. No chips tearout nothing, this is not how things usually go for me but Iím alsomusually in the clock trying to make sure my boss is not loosing but making money.

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  2. #47
    Join Date
    Feb 2015
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    Being I won’t get my panel spacers till Tuesday I won’t be gluing anything up till Wednesday. With that said I figured what’s the rush on the jambs and said let’s internet and watch football and relax. I can make the jambs between now in then in short order. If I don’t do any fancy joinery and just screw them togehter per industry standard I had better be able to build four of them in a day or I’m fired! In all honestly I have some joinery planned to make it fun and because I use screws day in and day out at work and bad moth it every step of the way. We will se how eager I’m feeling in the morning with regard to joinery vrs screw and the jambs.

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    And that’s it for now. Time to get fat!

  3. #48
    Join Date
    Feb 2015
    Location
    Beantown
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    Jamb stock milled.

    I have decided I’m not a fan of working with DF....

    Once this room is done so aren’t me a df....

    Tomorrow I’ll put them together. Well I may wait till I get hinges as to insure the material stays flat stickered on my bench.

    Panel spacers should be in tomorrow so I should be able to do final glue up of doors in the next two days..

    I might just get a couple days screwing with the Martin before my vacation is over if all goes well. Or I could sit on the couch and watch bad movies something I only do when I’m deathly ill ��

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  4. #49
    Join Date
    Feb 2015
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    Beantown
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    More progress.

    Got pulled away yesterday after only a couple hours work. I got a couple of the jambs dovetailed together.

    Complete overkill but it’s good for me to actually cut a dovetail once in a while for practice and also just so I don’t forget how. I restrained myself from getting overly fussy with these being they would be hidden. Instead I just did my best to get a good fit off the saw. Let’s just say they are not furniture grade.

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    Last edited by Patrick Walsh; 01-10-2019 at 12:31 AM.

  5. #50
    Join Date
    Feb 2015
    Location
    Beantown
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    Yesterday my panel spacers arrived so I was able to finally glue the doors up.

    Glue five doors together sounds like a quick simple task right. Wrong, I also had to re sand and put two coats of shellac on the panels prior to assembly.

    The panels came off the widebelt at 150 grit. I took them through 180-220 before shellac. I gave them two coats of shellac sanding between coats with 320 then again with 320 before glue up.

    I’ve never used shellac and I think I’m in love.

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    Then the shellac,

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    Panels have stayed very flat. So far I feel good about my decision to use solid 3/4 panels.

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    Stiles and rails the same. Nothing has moved at all.
    Last edited by Patrick Walsh; 01-10-2019 at 12:25 AM.

  6. #51
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    Feb 2015
    Location
    Beantown
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    I took the doors out of there dry fit in the clamps one at a time. This was the slow way but I was enjoying the work today and in no rush.

    I gotta say these panel buddy spacers are great! I hate spaceballs, these guys are just a perfect fit. The only thing a little pain in the rear end was the panel sizing and getting everything actually in clamps. Per the instruction and proper downsize of my panel the spacers get compressed 1/8 on all sides. This made getting tenon and mortise aligned a pain till I came up with a system.

    The solution was to assemble the top and bottom rail panel and put them in clamps with just right amount of pressure.

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    Last edited by Patrick Walsh; 01-10-2019 at 12:27 AM.

  7. #52
    Join Date
    Feb 2015
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    Beantown
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  8. #53
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    Feb 2015
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    Beantown
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    Everything in clamps. No major setbacks much to my surprise. I figured with the fragility of the df anything could go wrong at anytime.

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    Lunch, they need to make these in 40oz Saint Ides Crooked ale style

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    Nothing is quite as good as finding the leftover and now cold morning coffee at 8pm. It almost tastes better in the evening and full of dust.

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    Tomorrow I’ll finish the jambs then decide if I want to wait 7-10 weeks for hinges or go buy some Baldwin’s off the shelf. I’m leaning towards wait I just am scared to leave doors not hung for 2-3 months.

    Oh and either tomorrow or Friday I’ll throw these through the widebeltthrn continue on with coats of shellac.
    Last edited by Patrick Walsh; 01-10-2019 at 12:30 AM.

  9. #54
    Join Date
    Feb 2015
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    Beantown
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    It’s doesn’t feel like I did much today but I was busy all day.

    I started by taking six giant bags of chips to the dump. I needed my truck to transport the doors to work to sand them. The bed of my truck had become a chip collector full to the top of the cap. In bags of course but it was full!

    Anyway just a picture show. It was scary transporting these. I used moving blankets to move them. I ended up with one splinter tearing out. It small but on the edge of the where a pan;e and stile come togehter. I was pissed to say the least. I was also so nervous to dent anything at the wood is so soft. As I was bringing the doors back into my shop I did catch something and get a slight dent on the edge of a stile. A wet rag and iron took care of it but again for a minute I was pissed!

    The widebelt makes this child’s play. It really feels like cheating and imop is. I’m fine with it as at this point the doors look real tidy as if I actually paid someone to make them lol.

    They are sanded to 150moffmthe widebelt. I then took the time to route the edges with a 1/16 roundover bit then give all edges a quick handstand with 220. This was precautionary as to avoid a mishap in the way home. I still need to orbital them to 220 before more shellac.

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    Everything stying perfectly flat.

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    Everything home safe and sound for the most part.

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  10. #55
    Join Date
    Feb 2015
    Location
    Beantown
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    More xxxxxx

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    Tomorrow Iíll finish the two remaining door jambs and order the hardware.

    To any pro doorbuilders that might be reading. What is the best way to store these to assure they donít warp. I have over the years seen so many doors warp on site when the show up in jambs and get leaned against a wall for weeks or months awaiting install. Somtimes even a couple days and your in trouble.

    Iím pretty happy with the doors. I really want to retain the pale look of them post sand. Question to finishersmor thosemwith experience with shellac. If I just shellac and then wax with butchers wax but say buff out the shellac with a high grit paper as to get a mat finish prior to wax should I be able to get this pale tone coupled with a low low sheen?

    Thanks to all whom have offered me advice and or made recommendations along the way.

  11. #56
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    Apr 2017
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    Clarks Summit PA
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    Those are some fine doors Patrick. They will enhance your house.

  12. #57
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    Feb 2015
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    Beantown
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    I’ll never get out of them what I will have into them should I sell. But I sure had fun making them and I’ll enjoy them everyday.

    Finalized hardware today and ordered it. It’s a done deal now no choice but to go with the decision as it’s all made to order. I can hardly wait. It’s gonna be like Christmas morning all over again.

    I’m not quite as excited to mount it all but when it’s all said and done the finished whole should be approaching artwork vrs millwork and door hardware.

    Now I gotta get back to work and make the $$$ to pay for the hardware. I feel a little bit better knowing the company is probably a fairly small business and just maybe one or two of the people that will make the hardware at least enjoy and appreciate their jobs making things as I do cabinetry even though I’d much prefer to be making furniture or day high end passage doors and the such. I really do one maker to another feel good paying someone what they require to provide a high quality product as I feel so may want the best but are only willing to pay for mass produced.



    Quote Originally Posted by Mark Rainey View Post
    Those are some fine doors Patrick. They will enhance your house.

  13. #58
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    Apr 2017
    Location
    Chapel Hill, NC
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    43
    Really beautiful doors Patrick. Something to be proud of. Thanks for sharing your process.

  14. #59
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    Thanks for saying so and it’s my pleasure. I have learnt so much picking through others builds over the years..

    Quote Originally Posted by Michael Todrin View Post
    Really beautiful doors Patrick. Something to be proud of. Thanks for sharing your process.

  15. #60
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    Feb 2015
    Location
    Beantown
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    ...

    Shellac.....


    Two coats on panels sanded back to 320 nothing on stiles and rails.

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    Three coats on panels and one coat on stiles and rails.

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    I did this all with a brush cut by 1/3..

    Iíll sand everything to 400 next and switch to a pad for remaining coats. Iím half inclined to give the df a coat of the TruOil first. I just canít decide. The ayc is perfect with regard to tone, at least itís what I was looking for.

    I dint know what I dint know and in many cases Iím learning as I go. I tend to always try and take on a new task as I get bored doing the same thing over and over again. So I was doing some research on shellac application, I had had a idea in my mind and made up a couple samples based on those ideas pretty much comprised of rubbing on shellac then finishing with wax. So funny when I started reading about shellac application I quickly realized thatís called French polish lol..

    So at this point it looks like Iím gonna be French polishing five doors four jambs all the trim in the room and four large shoji screens lol. Ok maybe not the shoji as I know nothing about building them and fircall I know I canít finish them? Mostly Iím thinking about gluing the rice paper on.

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