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Here is the proposed drawing
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Here is a cut-a-way view of the mullions and hand
beveled glass
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Here is the exceptional 3" rough "pattern" grade
Honduras Mahogany
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I sharpened all of my knives
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and setup all of my tools with sharp knives and
cutters
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The rough lumber is cut out and allowed several
days/weeks to "settle down" and relax
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Then all of the skim planed to layout so that all my
grain matches
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It was a hot summer day ..... so I closed the shop
and went to sit in my grandsons "pool"
...... and laugh with him !!
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All boards are then straightened and flatted by
me
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...... and the planed to the thickness of
2-1/4"
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Then all the pieces are squared up and cut to width
and then length
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Each piece is shaped in three stages
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A door should be constructed
to grace a home for 100 years.
.......... why not!
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and the mullions are bored for 5/8" dowels that I
make myself
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...... here is a piece being "coped" on one of my
shapers
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a close-up of the coping process
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I make my own dowels, for the mullions, out of
Mahogany ..... so they will never rot !!
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here is an actual 3"+ mullion after being
coped
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Here is a cool picture of the machined short
mullions
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... here the long mullions are coped before
shaping
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Here the pieces are laid out
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.... and then each piece is machined and dry fitted
......
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....... till I get a perfect fit on each
piece
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Then the gluing process begins
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my friend Debra and another person helped pre-glue
each piece
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... and then we started assembling from the inside
out
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here we are applying more more covering of glue to
the splines before adding the side styles
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Then it is clamped together and the excess glue is
removed
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The corners are the "scrubbed" with water and a
tooth brush
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The industrial urea resin glue, I use, remains water
soluble for a couple of hours and then becomes waterproof
and I allow a full 72 hrs to cure
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...... and then hours upon hours of hand sanding
begins
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Furniture for the home !!
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Here I am mortising for a movable sweep
show
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And here I am adding the astragal and mortising for
the slide bolt
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Then we stain the mahogany with a warm brown which
is added to my varnish oil
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....... not bad huh !! It is so warm and
inviting
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Here the hand beveled Diamante Starfire is being
set
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View some custom
hand beveling by Iniquez Glassworks
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I also made another 20+ doors for the home ......
and custom cabinet doors
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Here is the finished entry
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