Our neighbor and friend is the general contractor on a building renovation in town that includes four apartments. He asked me to design and build custom face frames and double doors to finish off hot water heater closets in each apartment. The face frames and doors will be painted, and this project gave me a great opportunity to work down the inventory of hard maple I have on hand. The simple Shaker style door panels will be 1/2 birch plywood, and due to the size of the doors, each will be hung with three Blum soft-close cup hinges. This project is a nice way of having a product of my workshop be a part of our town!
This project is currently in the shop, so please check back for progress updates!
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- Apartment A
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- Apartment B
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- Apartment C
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- Apartment D
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- 4/4 Hard Maple Boards
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- 4/4 Hard Maple Boards
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- Blum 38N355BE08 Compact Soft-Close 1/2” Overlay Blumotion Hinges
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- Face Frame Components
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- Drilling for Kreg Pocket Screws
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- Assembling Face Frames with Glue and Pocket Screws
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- Each joint must be tightly clamped before installing pocket screws.
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- Bessey bar clamps and F-style clamps
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- Four Assembled Face Frames
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- Thickness Planing Door Components
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- Door Components Ready for Next Operations
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- Forming tenons on the rail ends
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- Rails and Stiles
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- Rails and stiles
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- Setting up 35mm Forstner bit for drilling cup hinge mounting holes
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- Drilling cup hinge mounting holes in one stile per door prior to assembly
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- Four custom sets of frames and doors required lots of notes
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- Breaking down half-inch plywood for door panels with the track saw
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- Ripping panels to width
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- Cutting panels to length with the cross cut sled
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- Cutting rabbets on the half-inch door panels to fit in quarter-inch grooves
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- Dry fit of door rails, stiles and panels
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- Door assembly
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- Assembled door sets ready for sanding and fitting to face frames
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- Shop made jig for drilling pilot holes in face frames for cup hinges
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- Final adjustments of door sets to face frames
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- Four sets of custom face frames and doors ready for delivery
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- Painted and installed by Jess’s crew at the Mack Building
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- Painted and installed by Jess’s crew at the Mack Building
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- Painted and installed by Jess’s crew at the Mack Building
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- Painted and installed by Jess’s crew at the Mack Building