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Trimming A Veneered Pine Door

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Project by ToddE posted 12-24-2007 09:13 AM 2172 views 1 time favorited 3 comments Add to Favorites Watch

Hello Everyone… I just thought that I would post this project that I just did for my wife. She initially wanted louvered bi-fold doors installed in our kitchenette. However, after I framed it in and primed the frame…she of course decided to change her mind. Now she wants two glass panel, pine doors installed. This was great, but the only problem is that the frame is 46 1/4” X 82”, which is what I needed for the rough opening for the bi-fold doors. The door frame is trimmed, drywalled and primed. There is no moving the dimensions of the casing. The smallest size doors that I could find were 24” X 80” glass doors. No big deal, just cut 7/8” off each door, splitting the difference on each side of the door. After putting the door on the table saw and fortunately just before I made my cut. I looked and saw this at the bottom of the door… Notice in the first project pic, where the writing is at the bottom of the door, that the entire thing is veneered. Each side is cored of three different chunks of pine and the door edge is veneered with a 1/2” piece as well. So you just can’t split the difference of 7/8”. To solve this, I cut 1/2” off the side I wanted the handle side to be. This gave me an end piece of 3/8” (1/8” curf). As you can see, the veneer is completely removed (left) and the glued inner pieces (right) are exposed. But I have removed the desired thickness.
Photobucket Then, I flipped the door over and set my fence at 23 1/4” and ran the cut, taking a 1/4” off. This gave me a 1/8” piece (1/8” curf), I set this aside for later use. Also, most importantly, I still have a 1/4” of veneered finish on this side of the door. See the first pic in the project photos. Then I set my fence at 23” and flipped the door over again and made a second cut off the handle side of the door. Remember, I still have 1/4” of veneer remaining on the hinge side, so I can now turn the door over and chisel the hinge pits out and hang the doors. Because the doors are facing each other, I now have a gap that I can deal with. My gap between the doors is a 1/16 over a 1/4 inch. This gives me some room for adjustment. After I tweek everything and get my final adjustments, I can now take my 1/8” veneer that I cut off earlier and glue it back onto the handle side of the doors and Vola! Now both the doors are even thickness and I have a veneered finish on both sides! This gives me an overall width of 23 1/8” for each door. I hope this helps anyone that got stuck like I did. I got my doors in and didn’t have to rip my door frame and drywall apart to please my lovely boss. By the way, you see pulls and not door knobs. I used “ball and pinion” catches in the tops of the doors. These are clean functioning and free up a lot of stuff hanging off the front of the doors. Especially when you have two smaller doors opening with each other.
Photobucket

-- Allegheny Woodshop





3 comments so far

View mrtrim's profile

mrtrim

1696 posts in 5372 days


#1 posted 12-24-2007 01:49 PM

good job todd ! and great blog as well . thanks for sharing . happy holidays

View Critterman's profile

Critterman

601 posts in 5302 days


#2 posted 12-24-2007 02:22 PM

Yeah, great blog, and the doors look great. Way to overcome the challenge.

-- Jim Hallada, Chesterfield, VA

View miles125's profile

miles125

2180 posts in 5498 days


#3 posted 12-24-2007 02:54 PM

Looking good Todd!

-- "The way to make a small fortune in woodworking- start with a large one"

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