advice on cutting a door.

[knight_toolworks]

a customer wants me to pocket out the door panel. this is a big door 82x42" 2" thick solid wood. the panel is 1 7/8 and will be 1.5" after pocketed out. the circles will be raised so most of the door will be pocked out. I am worried that the panel will warp. I suggested that they use two thinner panels with a foam core. this would let the panel be pulled flat after ti warps when I cut it.

http://i154.photobucket.com/albums/s266/knighttoolworks/posting/12C7B7E1-orig.jpg

[gc3]

if it is a floating panel captured in a stile/rail frame that is 2" thick, then the panel should be OK even if it moves from the machining. Once in the groove of the stile/rail it should come back to a flat panel. I have done panels similar to this and never have had a problem.

[knight_toolworks]

could you bend a 1.5" after cutting panel flat? I can see thinner panels if using two of them.

[gc3]

well if as you say most of the panel will be pocketed out...yes. what is the thickness of the rabbet on the panel for the stile/rail .5" or .25".

[knight_toolworks]

the panel is 1 7/8 and when done 1.5 so .375 pocket.

[gc3]

the panel in these doors is 1.75" thick, .625" deep carving each side which left a .5" "tounge" that fit into the groove of the stile/rail of the door. These panels did move after machining both sides, close to .375" warp...but were easily fitted into the stile/rail "groove"

are you machining a door already assembled or a new construction door?

[knight_toolworks]

I am just cutting the panel and two ends to get those loops. so once out of my hands I don't have to worry but I wanted to be up front with them about it. I have had enough things warp after cutting or even while cutting. this is a one sided cut with a flat face inside.

[gc3]

cut the panel, get paid then it is up to the door fabricator to make the door correctly...

[dubliner]

Thats a gorgeous door Gene. Lovely work.

[frank134]

Hi Gene,
It look like you make some real nice door. Would you mind if I ask you a few question? I have build kitchen cabinet , furniture and lot of other things. I would now like to build two new front door for my house. Each 36" wide x 114" tall for a 6' opening. I don't know why but I am a little scare about doing this. I have never build a front entrance door before. I plan on having a full etch glass panel ( one piece)for each door. I have a real good brass stop lock for the second door. Which going from top to bottom and a lever at the bottom that go on the inside of the rail. Which I am guessing I have to dado to put in or do you drill a hole for it. I have 9/4 white oak for this already plane and sitting for the last three month.
1. I don't know where to start.
2. what type of joint should I use?
3. Do I build the frame first? I am going to open the whole front of the house
4 How do I make is true? No wrap in it.
5 Any other things you could tell me.
Thank You
Frank




the panel in these doors is 1.75" thick, .625" deep carving each side which left a .5" "tounge" that fit into the groove of the stile/rail of the door. These panels did move after machining both sides, close to .375" warp...but were easily fitted into the stile/rail "groove"

are you machining a door already assembled or a new construction door?