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To get the best performance from your handsaws they need to fit your body and be properly set up. Host Ron Herman shares...[Read More]

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Sharpen Your Handsaws


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  Frame and Panel Construction, part 3: The Real Thing by Jim Harvey 1 of 7  


Parts one and two of this series showed construction of a small frame and panel assembly.

I made a half dozen of those as learning exercises for the final project, rebuilding the entrance to the crawl space in my tri-level home. This may be way over engineered but the old doors are truly ugly, made from thin paneling covered with contact paper, and besides, I wanted to learn how to make raised panels with hand tools.

Most of the techniques I used came from the Woodwright’s Shop episodes mentioned in part 2, this part 3 will document differences needed to complete the larger scale crawl space entrance.

I built a new outer frame from 2 inch pine to fit the existing opening. I have to admit not using hand tools for that as I recently acquired a Kreg K2 jig and wanted to try it out. Also the rails on a butt jointed frame would be four inches shorter than a mitered corner frame which worked out much better with the 72″ stock I had.

Pencil study for cut list.

The outside dimension of the doors is determined by the inside edges of the outer frame so I propped up the outer frame and centered the stile pieces leaving about 1/16″ gap at the sides.

Outer frame with door stiles.

Each pair of stiles was checked for parallel with pinch rods. Everything came out OK with very little tweaking. Stiles were marked top and bottom where they touched the outer frame. Then I centered the rail blanks on the stiles and marked where they touched the rails left and right. Those four lines define the dimensions of the doors.

Checking stiles for parallel.

Learn how. Discover why. Build better.
1 of 7  

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