Doorbell Cover

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Project by AandCstyle posted 08-18-2018 12:21 AM 1638 views 4 times favorited 19 comments Add to Favorites Watch

This is my version of a project made and designed by James E McIntyre. I thank James for his guidance and assistance. This is a great little project that used up a few scraps and it required me to buy a new router bit. :) I attached the sides to the top and bottom with dominoes. I ran a groove in the sides with the table saw. The new bit was used to cut the dados in the top & bottom to receive the face which I milled to just under 1/8”. I had a couple false starts on the face but finally figured out that the 1” square mortises need to be cut in thick stock, mine was about 1/2”. I, then, thickness planed it to about 3/16” (a band saw could be used) and finally used the drum sander to reach the final thickness. I put about 0.25 ml (aka a dab) of glue at the top and bottom inside center of the face to hold it in place. My doorbell was mounted horizontally so I had to make this wide enough to cover the unpainted portion of the wall. All in all, it was a fun little project and I learned a few things along the way. Thanks for looking.

-- Art

19 comments so far

View Dave Polaschek's profile

Dave Polaschek

4586 posts in 1220 days

#1 posted 08-18-2018 12:24 AM

Looks like that’ll dress up the doorbell nicely, Art!

-- Dave - Santa Fe

View oldrivers's profile


1989 posts in 2204 days

#2 posted 08-18-2018 01:56 AM

Beautiful Piece of work, Great job.

-- Soli Deo gloria!

View Andre's profile


3083 posts in 2444 days

#3 posted 08-18-2018 02:08 AM

Very nice! Now I need to go make one for my house!

-- Lifting one end of the plank.

View Jerry's profile


3368 posts in 2286 days

#4 posted 08-18-2018 02:14 AM

You’re killin’ me Art, another beauty to be sure.

-- There are good ships and there are wood ships, the ships that sail the sea, but the best ships are friendships and may they always be.

View sras's profile


5310 posts in 3767 days

#5 posted 08-18-2018 04:12 AM

Beats plastic any day! Looks great.

-- Steve - Impatience is Expensive

View JimYoung's profile


349 posts in 2225 days

#6 posted 08-18-2018 12:26 PM

Nice little project.

Any advice on cutting the square holes? I’ve got a small project going, and had a heck of a time with those.

-- -Jim, "Nothing says poor craftsmanship more than wrinkles in your duck tape"

View AandCstyle's profile


3272 posts in 2895 days

#7 posted 08-18-2018 12:49 PM

Thank you, everyone! :)

Jim, I carefully laid them out and marked them with a pencil, then applied blue tape along the lines to act as a guide for the chisel. A cutting gauge might have worked even better. Then I chiseled out the squares. This has to be done on thick stock (I used 1/2” on my third attempt) because thin stock will split when trying to cut the mortises no matter how careful you think you are being. DAMHIKT haha I use the chisel to cut straight down on the 4 sides, then I pare a bit off going with the grain starting close to the far side of the square and work my way paring off just a bit (1/8” or less) at a time. I end up with something that looks kind of like pages in an open book or feathers. Then I do the same thing working from the opposite side. Once that is done I redefine the 4 walls of the mortise with the chisel and repeat. I am not much of a hand tool worker so I am certain there are others here that can describe the process better of have a better way of doing it or take a look at Youtube. I’m sorry I can’t give you a better answer.

-- Art

View Luddite's profile


233 posts in 1876 days

#8 posted 08-18-2018 01:16 PM

Very nice Art.

You know a bench mortiser would’ve been easier. ;)

-- T Loftus -- Just on the edge of common sense

View splintergroup's profile


3295 posts in 1860 days

#9 posted 08-18-2018 01:45 PM

A real dinger Art! Your “scraps” look like my latest haul from the wood supplier..

Good work on those holes, I would have just sliced it up, removed the squares and glued it back up. Probably would have taken twice as long as your meat powered tool approach 8^)

You really need to go full James McIntyre on your house, I’m sure that laundry room could use some TLC 8^)

View GR8HUNTER's profile


6961 posts in 1350 days

#10 posted 08-18-2018 02:16 PM

much better then plastic 100 times nicer looking also ….. GREAT JOB :<)) GRATZ TOP 3

-- Tony---- Reinholds,Pa.------ REMEMBER TO ALWAYS HAVE FUN

View Mark's profile


1033 posts in 2612 days

#11 posted 08-18-2018 05:28 PM

That’s a cool idea Art. Hope ya don’t mind if I borrow it.

-- Mark

View helluvawreck's profile


32086 posts in 3504 days

#12 posted 08-18-2018 06:30 PM

You did a beautiful job on this cover.

-- helluvawreck aka Charles,

View AandCstyle's profile


3272 posts in 2895 days

#13 posted 08-18-2018 08:43 PM

Again, thanks! :)

Terry, the mortises are 1” square so a bench top mortiser would not have adequate capacity, at least any I have ever seen. But, if I ever decide to make another one, I’ll look into buying one of these bad boys. haha

Splint, do you think you could get all the tiny parts to properly align and hold together during sanding?

Mark, be my guest because I stole it from fellow LJ James E McIntyre.

-- Art

View James E McIntyre's profile

James E McIntyre

628 posts in 1930 days

#14 posted 08-18-2018 09:24 PM

Art. It came out much better than you discribed. What a wonderful job! I like the way you beveled the top, a great addition to the project. I think your the most prolific lumber jock on this sight. You should sell some of you pieces on etsy. I’m sure you would recup you domino investment quickly.
Keep them coming I really enjoy your work.

-- James E McIntyre

View dannmarks's profile


1017 posts in 1219 days

#15 posted 08-18-2018 10:39 PM

Always fun to see someone have fun making such things. Very cool.

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