how would you make these doors?

[Warren Lake]

mortise and tennon, mitred profile.

[Mark Wooden]

I've done doors along those lines as 9 pc doors where I offset t&g'd a thicker band to the 1/2" panel(mitering the band) and then cut the necessary tongue on the band to fit the stiles and rails. My difference was a profile at the panel and I only had to do 8 doors.
If you have to do 90, getting a custom C&P set is most viable

[lowell holmes]

I would experiment on some small samples until I found what I like.

[David Zaret]

yep. tomorrow i plan on building a few mock-ups to get the proportions right. thanks for all the feedback - i'll report back once i determine the solution.

[johnny means]

I would attach a proper cost to each and the client would choose.

[Bruce Wrenn]

Sub them out! Hundreds of door companies that can deliver completed doors for less than your material costs.

[johnny means]

Sub them out! Hundreds of door companies that can deliver completed doors for less than your material costs.

Could you send me a list of those companies.

[Jared Sankovich]

Could you send me a list of those companies.

I'd like a copy of that list.

[David Zaret]

i "solved" this by using parts to a few of my freeborn cope and stick sets. the challenge was to get the "applied moulding" piece as thin as possible, and unfortunately, i could only get it to 5.5mm, the thickness of the thinnest groover i have in the freeborn sets. so, what you see in this picture is a 5.5mm thick "moulding" portion, 12mm wide, on top of a 1/4" tongue/groove for the panel and cope and stick. it's a tight joint with a ton of glue surface area, so i'm not worried about anything coming apart (especially with the panels glued in). but, i wish i could have figured out how to get a 4mm thick moulding profile, instead of 5.5. 5.5 is a bit heavy for my taste.

joe, i spent almost two hours trying to solve this with the multi-use cutter and a groover, and determined it would be very tricky to do in a reasonable number of passes. the little wing cutter on the multi-use is 4mm thick, which is perfect, but does a maximum depth of cut of 8mm, which isn't enough. i could do it with spacers, and a 4mm groover, but it would be at least two passes per cope and stick, vs. one each for the freeborn setup. so, that's that.

if anyone has any other brilliant ideas, i'm all ears. thanks for the assistance.

--- dz

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[David Zaret]

120 doors and panels later, they came out great. tight joints, and plenty of glue surface. the client is very happy.


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[Joe Calhoon]

Looks good Dave!
What did you end up using for cutters?

[David Zaret]

joe, i ended up taking cutters from my various freeborn 6-cutter stacks, customized spacers, and good programming on the martin. once i dialed it in (and sped the spindle up to 10k), i got great results.

thanks for your help, as always.

--- dz