Very Cool!!!!! Great millwork. RIch (PT-2)Greetings everyone. Many thanks for your valuable comments and 'likes'. Internal structure will require many entry doors, so I took a break from main construction and thought for a moment about doors. There are many different styles of doors but they are all made the same way. I took the door style sample from the AOTS book, and modify to suit my taste.
So let's begin. Doors in the kit provided with panels laser etched, and looks a bit small to the scale. We will be using Pear and boxwood as the main material and will make them a bit bigger to fit the scale. This is not the final design, and it may need more modifications down the road, But I will most likely use the same techniques and material. First, I cut all necessary strips of various dimensions.
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Started with panels as they require some 'fancy' work. Here is comes handy my ProxxyMill, very happy to have one, it is a great tool. To make those panels 'fancy,' I made a simple jig.
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The round bur is used as the router bit, Stock of wood slides against the jigs border while the bur removes the wood. Start with a touch of the edge of the wood and slide until fully complete. Before lowering the burr, switch to another side and complete it. Now lower the burr, but don't lower too much, it is better to remove a small amount in one pass. Choose alternative sides until you are happy with a result.
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Pretty cool, right? The stock panels already 'fancy', but I made a further decision to make it even fancier. I found a very small star endmill, and use it to make a small grove on top. The process of removing wood is the same as for the round bur.
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Here you go...now the panel looks real 'fancy' and the actual door is ready to be assembled. The door frame consists of the top rail, bottom rail, lock rail, hinge stile, and lock stile. All parts were cut by size and assembled using a flat surface (ceramic tile in my case) and machinist square.
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First, all rails glued to the hinge stile. Once the glue is set, the lock stile is glued. Use machinist square to control squareness across the board. Once all dried, the door\s ready to sand. 320 grit paper was used follow the 400 grit.
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...and here are the doors
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The left one made out of boxwood, both the middle doors made with boxwood panels and Pear rails and stiles. The right one was made out of Pear. The supervisor made inspections.
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I think he is happy with the result...thus far.
Thank you all, to be continued...