Door Fitting

Door Fitting

Paul goes through the process of fitting a door into a cabinet opening. The first step is to check the door is straight and true. Once that is done, Paul shows how to create a slight taper to the inside edge to help ensure a tight fit. He fits the stile, then the head and then the foot of the door, with a slight consistent gap all around. With the door fitted, Paul fits the hinges and shows what to look out to ensure tight and square hinges. He pre drills and then fits the screws, and shows how to layout the middle hinge.

Door Making episode 4

Door Making episode 4

We’re ready to assemble the door with the hammer and clamp, checking the joints, to get accurate measurements for the panels. Once the panels are cut to size, Paul discussed the options for fitting them to the groove. Paul uses a marking gauge to mark his recess, then rebates the panels, introducing a few different techniques. With that done, there is the final dry run before systematically gluing up the door.

Door Making episode 3

Door Making episode 3

There are lots of options of how to do the panels in the door. Paul shows how to insert a central perpendicular piece in place. He shows how to layout to ensure crisp mortice and tenons, after ensuring everything is square and aligned. Then comes the fitting of the tenons to the mortises to finish the initial door frame construction.

Door Making episode 2

Door Making episode 2

It’s time to mark the gauge lines for the tenons of the rails. Then Paul shows a few techniques for cutting the tenons using a combination of the saw and chisel, before using the router to fit them to the mortises. He cuts the haunches and shows how to make sure to align the joints. He then assembled the whole frame to check for twist and cleans them up.

Door Making episode 1

Door Making episode 1

Paul discusses the elements involved in making a twist free door and checks and prepares the stock. We then move onto cutting the groove, using a gauge to help prevent tearout. With the frame grooved, Paul shows how to layout the frame in preparation for cutting the mortises.

Wall Hung Tool Cabinet – episode 10

Wall Hung Tool Cabinet – episode 10

The next section is the back frame, which holds the main carcass square and solid. Paul lays out the mortice holes and then it is time to plough the groove and cut the mortice and tenons according to the drawings and using the same techniques as the divider panel. With that together Paul measures up and cuts the plywood panel, before checking the whole frame for fit and gluing up.