Woodworker's Journal fall-2010, страница 47
Eight Steps to Flat-Panel Doors Apply glue to the exposed edges of these biscuits. Stand the bottom in place and make sure its front edge is flush with the sides, as shown on page 44. Apply a couple of clamps, temporarily, to seat the bottom against the side. You want the box to be square, of course, so use corner clamps or assembly squares to hold these two panels at right angles to each other. Stand the rails in their places, again making sure the front edges are flush with the sides. Then apply glue and insert the biscuits in the open slots in the bottom and rails. Carefully set the second side in place. Apply clamps at the four corners of the box. Measure the diagonals front and back as you tighten the clamps. With the box squared and firmly clamped, drive the assembly screws. At each marker hole, drill and countersink a proper pilot hole and drive in a drywall screw. With that done, remove the clamps and right the box (check for square). Leave the back off until youve installed all the internal hardware. Making Doors These flat-panel framed doors are easy to make. The rails and stiles are joined with groove-and-stub-tenon joints around a 1/4" plywood panel (see photos at right). Plow the l/2"-deep grooves in both rails and stiles with a 3/16" slot cutter in a table-mounted router. Make two passes to center the groove. Cut the l/2"-long stub tenons with a large-diameter straight bit on the router table. Glue and clamp each door, making sure it is square and flat. Cup hinges mount the doors to the box. The hinge is mounted to the door and a base plate is screwed inside the cabinet. Clip the two parts together to hang the door. While you must locate the parts accurately, the hinges can The door's rails and stiles are assembled with groove-and-stub-tenon joints around a 1/4" panel. Plow the 1/2 "-deep grooves in both rails and stiles with a 3/16" slot cutter. Cut the 1/2"-long stub tenons with a large-diameter straight bit on the router table. Dial in the bit settings by making as many test cuts as necessary on scrap material first. Glue and clamp each door, checking for square as you go. Leave the stiles a bit overlong, trimming them after glue-up. Trim the stiles with a combination blade on the table saw, guiding the cut with a sliding table or a crosscut sled. At this point in the process, it's critical that the doors are square and of identical size. Locate the cup holes on the door stiles and bore them with a Forstner bit. Pencil marks on the drill press fence can serve to index these hole positions. A jig is available to locate the two hinge base plate screw holes in relation to the case edge. Clamp the jig to the side and drill screw pilot holes with a self-centering bit. Press the hinge barrel into the cup holes, align them with a square, and fasten them in place. Screw the hinge baseplates into place and clip the hinges together to hang the doors. Adjust the hinges so the doors hang evenly in their openings. Fall 2010 47 |
