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After several door ideas ....... here is the final
design
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All of the clear glass is 3/4" of an inch
thick
and hand beveled to a compound center peak
The cobalt blue glass is 1" thick
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Here are are several different door ideas
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Below is the history of how these beautiful doors
are constructed
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The rough Mahogany is joined flat and then
surfaced
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Here are some of the pieces out of the
planer
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Then each piece is cut to width and then
length
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since the mullions are so narrow I cut away most of
the material before I shape them in the shaper
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....... and the the cross mullions
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Then the mullions are bored for dowels on the end
grain
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Then the pieces are checked for a perfect vertical
fit
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Then I start machining the 48 short mullions. I
start by coping the end grain and fit and refit until it's a
perfect fit
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and then I shape the molded edge and rabbit ......
pretty tricky
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The we cut clamping blocks to fit between the
mullions so that we can clamp across the entire door ......
it takes hours of fitting ..... and a few tricks !!
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each mullion will be glued on the end grain at least
3 times before assembly
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and the the "mapped" pieces are placed on the
vertical mullions
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All of the excess glue is removed and
washed
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...... we then "toothbrush" the glue out of the
corners
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... and blow the excess water
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Here each door will stay in clamps for 4 days .. for
a full cure of the glue
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while under clamps ..... we measure the glass
openings ...... time to order the glass
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Each and every molded edge is marked with chalk
....... then hand sanded .... when the chalk is gone .......
it's done
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Then all of he surfaces are machine sanded to a
furniture grade of 220 grit
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...... here's a cool picture of he "door (dust) we
left behind" !! ........
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All doors are made a specific amount oversize and
the cut on all for sides, to finish size.
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we use 4/4 stock and laminate it together then
thickness sand it
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The second door is finish sanded .....
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Here are the doors with the 3rd coat of varnish
oil;
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...... and wiped down
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Here is the first door, just oiled. This door will
receive 3 more coats of our varnish oil
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........ it takes almost 3 hours, just to wipe off
the excess varnish oil
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........ and the "bleed out" wiped off for several
more hours
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Here are the doors with the 4th coat of varnish
oil;
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Here I am mortising the jambs for the
hinges
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The last coat of varnish oil on the jambs
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and the the jambs cure for 3 days
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Wiping down the 5th coat of oil
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Here we sand the stops before oiling
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It is hand beveled to a peak
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Here is some of the cobalt glass
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Here is an interesting refraction of light
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The prismatic effect bends images
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Click
Here to see more of the Diamante
Starfire
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Here are just a few of the stops for the
doors
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Here we are cutting the short stops
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.... and here I am cutting the long stops
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Here is a piece of the Cobalt Diamante Glass and the
clear Diamante Starfire
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