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!
Apartment D
Apartment C
Apartment B
Apartment A
4/4 Hard Maple Boards
4/4 Hard Maple Boards
Blum 38N355BE08 Compact Soft-Close 1/2” Overlay Blumotion Hinges
Face Frame Components
Drilling for Kreg Pocket Screws
Assembling Face Frames with Glue and Pocket Screws
Each joint must be tightly clamped before installing pocket screws.
Bessey bar clamps and F-style clamps
Four Assembled Face Frames
Thickness Planing Door Components
Door Components Ready for Next Operations
Rails and stiles
Forming tenons on the rail ends
Rails and Stiles
Setting up 35mm Forstner bit for drilling cup hinge mounting holes
Drilling cup hinge mounting holes in one stile per door prior to assembly
Four custom sets of frames and doors required lots of notes
Breaking down half-inch plywood for door panels with the track saw
Ripping panels to width
Cutting panels to length with the cross cut sled
Dry fit of door rails, stiles and panels
Cutting rabbets on the half-inch door panels to fit in quarter-inch grooves
Door assembly
Assembled door sets ready for sanding and fitting to face frames
Shop made jig for drilling pilot holes in face frames for cup hinges
Final adjustments of door sets to face frames
Four sets of custom face frames and doors ready for delivery
Painted and installed by Jess’s crew at the Mack Building
Painted and installed by Jess’s crew at the Mack Building
Painted and installed by Jess’s crew at the Mack Building
Painted and installed by Jess’s crew at the Mack Building