mahogany door

  • Advertise with us
Project by moonls posted 05-13-2010 03:49 AM 2585 views 2 times favorited 10 comments Add to Favorites Watch

This mahogany louvered door was designed to fit the entrance to an interior boat compartment. The dimensions are 20” wide, 59” high, and 1” thick. I found directions on the internet for making the 2 jigs to rout out the slots in the stiles to receive the slats. I Practiced routing the slots on pine first to make adjustments to the directions which used 1 3/8” thick lumber since my door was only 1” thick. By using a 25 degree angle, I could cut slats that were 1 1/4” wide and 1” apart for proper overlap.

After dry fitting all the pieces, I used a slow-setting waterproof glue to allow time to get all the slats inserted into the stiles as well as the mortise & tenon joints assembled. I didn’t want the glue to start setting up during this tricky process. Finally the door was sanded to 220 grit and finished with 3 coats of spar varnish.

If I make any more louvered doors, I’ll need to construct a better jig that will speed up the routing process. This door had 48 slats which meant aligning the jigs 96 times!

-- Lorna, Cape Cod

10 comments so far

View grizzman's profile


7836 posts in 3808 days

#1 posted 05-13-2010 03:57 AM

you did a beautiful job lorna…i love the mahogany…and the building technique is bar none…great job…i got a peek of it from ellen…so i was prepared for your posting…glad you got it posted…your first project…congrats…grizzman

-- GRIZZMAN ...[''''']

View PurpLev's profile


8551 posts in 4153 days

#2 posted 05-13-2010 04:03 AM

this looks fantastic Lorna! the lumber is beautiful, and the finish is spot on.

as for a jig to speed up the process, there are probably several ways to go about it. either routing freehand, or using a router table with an angled crosscut sled and a repositioning fence.

-- ㊍ When in doubt - There is no doubt - Go the safer route.

View ellen35's profile


2742 posts in 3937 days

#3 posted 05-13-2010 12:23 PM

Looks as good in pictures as in person!
Very nice work… and a difficult but rewarding assembly.

-- "Don't let the perfect be the enemy of the good." Voltaire

View Cher's profile


962 posts in 3598 days

#4 posted 05-13-2010 06:31 PM

Your hard work paid dividends. Excellent job Lorna.

-- When you know better you do better.

View JAGWAH's profile


929 posts in 3588 days

#5 posted 05-13-2010 07:38 PM

Norm Abrahms of New Yankey fame made an exceptional jig in one of his episodes. The setup looked like a roe of cheverons that would guide your plunge router cutting both sides at once.
I made the jig and built over a dozen 20” x 72” cypress shutters for a client. I’ll see if I can find more info on it.
The louvre jig made on NYW was in the 2 part program on jigs No 0101 & 0102.
They were the 1st 2 shows of the 13th season.

BINGO check 10 minutes into the video. It is a foriegn site but I found no problem.
Here’s one source

-- ~Just A Guy With A Hammer~

View littlecope's profile


3073 posts in 4006 days

#6 posted 05-13-2010 08:44 PM

That came out Great, Lorna!! I think Jagwah is onto something… There’s got to be an easier way! :)

-- Mike in Concord, NH---Unpleasant tasks are simply worthy challenges to improve skills.

View Lenny's profile


1638 posts in 4031 days

#7 posted 05-14-2010 03:54 AM

Well done Lorna. It looks great. I have never worked with mahogany but most I have seen is darker and more brown in tone. This is lighter and pinkish in color pre-finished and appears more amber or honey colored with the varnish on it. Very nice looking wood. Again, great job.

-- On the eighth day God was back in His woodworking shop! Lenny, East Providence, RI

View Karson's profile


35201 posts in 4905 days

#8 posted 05-20-2010 02:08 AM

A great looking door. Nice construction.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Appomattox Virginia [email protected]

View a1Jim's profile


117721 posts in 4081 days

#9 posted 05-20-2010 03:27 AM

Looks great welll done

View Dusty56's profile


11852 posts in 4192 days

#10 posted 01-15-2011 06:07 AM

A lot of work for sure , but the end results are fantastic , Lorna : )

-- I'm absolutely positive that I couldn't be more uncertain!

Have your say...

You must be signed in to post the comments.

DISCLAIMER: Any posts on LJ are posted by individuals acting in their own right and do not necessarily reflect the views of LJ. LJ will not be held liable for the actions of any user.

Latest Projects | Latest Blog Entries | Latest Forum Topics