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Chisel Cabinet Days 10-14
Entered: 2010-02-05
Edited: 2010-02-05
Type: woodworking

Now that the door frame is completely finished it's time to start working on the panel for the door. The board I've chosen to for the door panels is somewhat special to me, it's a pine board that used to be a shelf under the first workbench I built for myself. It's warped and dirty and has a couple big knots in it but after many years of service I think it deserves to stay on as part of a shop fixture.

After flattening and squaring up the board I cut a shallow rabbet all along the back edge of the board, just deep enough so the back of the panel will be more or less flush with the rails and stiles when installed.



Next step is to define the area you want raised. Raising in this case just means that the outer border of the panel will be planed down at an angle until it fits the groove in the door frame. This adds a lot of depth and visual interest to the door and is more attractive than just a simple flat panel or plywood. After marking out the field with a marking gauge I like to take my plow plane, set to take a very fine cut, and cut a very shallow groove just outside the area to be raised, about 1/16" deep. This creates an attractive "step" in the field and is one more point of visual interest for light to play on. After creating the step I just go around the board with a jack plane (for working with the grain) and a low angle block plane (for working across the grain) until the edge of the panel fits the groove in the frame.





The small little piece I use to test fit is called a mullet. I have no idea where this name comes from but I'm pretty sure it's related to neither the fish nor the hairstyle.





Whenever I'm going to capture a panel in a groove like this I prefer to pre-finish the panel before gluing up. For starters it's just easier to get the panel looking nice when you don't have to work into tight corners. Second by applying a finish and topcoat of wax before gluing up the frame it's easier to slide it into the frame and the wax keeps any stray glue from sticking to the panel.

After finishing the panel it was time to glue up and install the door:





I just have to build the second door and the French cleats for hanging it on the wall next. As far as blog updates go not much left I'll cover the cleats and then a final picture with both doors installed. I have more chisel storage to build into and there's plenty of room for other tools to live in there, especially on the inside of the doors but none of that will happen right away and won't be a part of this series.




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