Here's a saga... This was supposed
to be a wedding present for my friends the McDonoughs - it was finally
delivered 'round about their
2nd anniversary. Sorry for the delay
guys, only you will ever hear the full story ;)
The concept - there were other designs, but this one won out...
The guilty party
- procrastinator extraordinaire.
The home of the door - OneTwo
The wood packed
on the java-mobile - all the door parts came from one tree...
The owners
- little did they know it would take so long (evil chuckle)
Ripping the
4 pieces to width
One side of each ripped
Ripped and ready
for planing
Planer on
a temporary strongback
Here's a project - "Some
Assembly Required" - nice clean crisp chips
Smooth
and planed to thickness
Spline grooves
between pieces
Tuning
up the tools - nice chips :)
Joint sample
- testing spline sizes
Layed
out for gluing - Glued...
Done gluing
- I used Gorilla Glue for the first time - next time I get more dropcloths...
Dry and
stood up to peek underneath
Cut square and straight - It's
a slab!!
Laid
out for pattern transfer
The full size pattern
Hounds heads - tree
barkers
Hogging out
the big stuff with a router - It's a Bosch 1613EVS plunge router (3.5 HP)
All roughed out - now comes the hard part
OneTwo
Smoothing
out the background
Splined ends
- the checking was getting bad and I had to put something in there to hold
it together - there's more hardware behind the wooden spline
Typical 'before'
background
After...
More checking
- this was filled just after the final finish - yes, after...
Checking - there were a couple of places
you could see through the door - yikes!
Start 'weaving'
The raised
portions here are about 3/16" wide...
Rather than a simple crossing of the bodies
I thought I'd tangle them up a bit...
Early face
detail - one of the teeth actually got lost in the Shop-Vac and I had to
dig through 5 gallons of chips to find it... yeesh...
About 90% done OneTwoThree
Partially Varathaned OneTwoThreeFour
- 5 coats all over...
Building the frame - OneTwoThree
- Thankfully there was no drama while building it - or installing the hardware
*phew*
Framed and
ready
Knock Knock...
Done but
for the crack sealant - that was the last thing before crating and driving
it back home...
Well, maybe not the last thing...