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  • A couple of doors

    This may take a few posts to get all the photos posted.

    I was tasked with building a couple prototype doors. Got the job on Monday, the finished pieces had to be in Cleveland by Friday (today).

    712da746aca9ab87e1724024a87683a1.jpgThe drawing I received.
    I was told the material had to be Asian Mahogany. More on that latter.






    1436c2bff043b0afb78777416efe35e4.jpgDue to the fact that the vertical parts of the reversed diamond had horizontal grain, I had to size and seam the veneer.





    0b0091b4ae04709ec7e473bcf861950d.jpgThe four pieces of veneer stacked on top of each other. The back board is a waste piece.




    9d48a21b0ef8376bd0bc9675b4b79a7d.jpgRail in place. Due to the fact that the panels will go into a groove, I had to adjust the rail so the corners would line up. I set it 1/2" inboard of the corners. I set the saw depth to just cut through the veneer.



    bd324efc5bd7343218130b11b4f1d1f1.jpgCuts made, did I ever mention I love my rail saw. I know each kerf will take 2.2mm, so I adjusted for that also in the layout.


    Tom
    Last edited by tjbnwi; 12-14-2012, 10:13 PM.
    http://chicagocraftsmen.org/2011/06/261.html

    Check with the AHJ, what we say doesn't matter.

  • #2
    Re: A couple of doors

    365dd54ba63f30828f121c457405a86b.jpgNow is when I admit, I have no clue what I'm doing. I knew I did not want to use contact adhesive, So I chose TB III. More open time then II less open time than II extended. I taped the seams tight, spread the glue, placed the veneer on the backer, bladed in, then separated the veneer from the backer. I find that this gives you a little grab when you reset the pieces. Aligned the veneer.


    63d0d2aff7da0bb13aae80c88e3e4b9c.jpgIn the previous photo you may have noticed a plywood box standing next to the panel. Well that is half of my portable bench. I made the torsion box years ago. It travels with me often. I could not quickly make a vacuum press large enough to "clamp" the veneer. So the halves of the bench and some bar clamps came to the rescue.


    94f48a987789c30c73620be6bacda7a6.jpg

    9c64f41f98fe44c689fa6182172af888.jpg

    168711a2b1e3c79743ce44c51c91d620.jpgThe panels after being in the "press" overnight.






    Tom
    http://chicagocraftsmen.org/2011/06/261.html

    Check with the AHJ, what we say doesn't matter.

    Comment


    • #3
      Re: A couple of doors

      d9310ec310906bd9fb8b15b391f6a951.jpgI guess I missed taking photos of a few steps. Grooves cut, Domino holes mortised.




      bf499a080e95a60d959511b9cd2c5054.jpgI pre-stained the edges. I was sent a color sample on quartered white oak. It took the blend of 5 dyes to match the sample color. The wood type would not allow the black darting in the white oak to be matched.




      0f2f64280d9b69179cd4b86f7c63a176.jpg



      3bcc34c38b3a9d1b02fe936b3550856c.jpgPanels dyed.






      Tom
      http://chicagocraftsmen.org/2011/06/261.html

      Check with the AHJ, what we say doesn't matter.

      Comment


      • #4
        Re: A couple of doors

        219caeaee4bddaa661d2a16e888af223.jpgSo I get a phone call, "forget the panel grain, we want it white, stain the frame though."



        There are no words.


        Tom
        http://chicagocraftsmen.org/2011/06/261.html

        Check with the AHJ, what we say doesn't matter.

        Comment


        • #5
          Re: A couple of doors

          Just kidding. I sealed the backside of the panel with white paint.

          673cec934457e0cce7598fcafc93abfc.jpg

          0643559729604eac20bfffda2e354a4f.jpg

          0c47a6f5b65374ae92db25d45049ac6a.jpg

          22de8a821bdaddd7b912c35688684d3b.jpg

          9b5061c2abff17f2f4b391eb3f1c6eb7.jpgThe finished doors after overnight cure of finish.





          270 more to go. Plus the vanity valances and storage units.


          Tom
          Last edited by tjbnwi; 12-14-2012, 09:55 PM.
          http://chicagocraftsmen.org/2011/06/261.html

          Check with the AHJ, what we say doesn't matter.

          Comment


          • #6
            Re: A couple of doors

            Now I need you wood and veneer gurus help.

            As I stated the the spec was for Asian Mahogany. I found a definition of it online, can't find a supplier. None of my suppliers have heard of it let alone can find it. One suggested it may be plantation raised Fiji Mahogany, claims he has seen it and it is knotty and wormy. Anyone heard of the speced wood? If so any info would be appreciated.

            As you can see the rails and styles were solid African Mahogany. What I need to know from you veneer guru's is--do you know of a supplier who can produce the veneer over an OSB core. I do not want to use MDF for this. I'm not confident in the roller hardware staying in place. I've seen to many screws pull out of MDF. I hope also to have the panels veneered, that can be over MDF or OSB.

            If I cannot find the Asian Mahogany and have to go with a solid, I going to recommend Sapele, your thoughts on that would be appreciated also.

            Tom
            http://chicagocraftsmen.org/2011/06/261.html

            Check with the AHJ, what we say doesn't matter.

            Comment


            • #7
              Re: A couple of doors

              Have searched keruing or apitong and even meranti and luan may fit; "Asian Mahog." isn't a species but a referential description.
              “I find the curiosity of our men with respect to this animal is pretty much satisfied.”
              ~ Meriwether Lewis

              Comment


              • #8
                Re: A couple of doors

                Looked at kerning, nothing of any quantity available here. Could not find an on-line supplier either.

                Ya, mahogany is a really over used word for woods that are not mahogany.

                Luan is Philippine or sometimes referred to as genuine.

                Tom
                http://chicagocraftsmen.org/2011/06/261.html

                Check with the AHJ, what we say doesn't matter.

                Comment


                • #9
                  Re: A couple of doors

                  Beautiful work, Tom!

                  My first thought on seeing the spec for Asian Mahogany was they probably meant Philippine Luan.
                  Joe Adams
                  Deep Creek Builders, Inc.
                  Houston, Texas

                  Comment


                  • #10
                    Re: A couple of doors

                    Just found this link. Looks like some good info.

                    http://learn.builddirect.com/Hardwoo...asian-mahogany
                    Joe Adams
                    Deep Creek Builders, Inc.
                    Houston, Texas

                    Comment


                    • #11
                      Re: A couple of doors

                      If you need veneer panels made up check out these guys.


                      http://www.navyisland.com/
                      there is ALWAYS a better way waiting to be discovered-
                      yfc

                      Comment


                      • #12
                        Re: A couple of doors

                        Joe,

                        I believe that is one of the few sites I found. Looks as if flooring may be available not much else.

                        Reads as if finishing would be a challenge.

                        Thanks for the compliment.

                        Ottoman,

                        Thanks for that link. I'll check with them tomorrow or Monday.

                        Tom
                        http://chicagocraftsmen.org/2011/06/261.html

                        Check with the AHJ, what we say doesn't matter.

                        Comment


                        • #13
                          Re: A couple of doors

                          Originally posted by tjbnwi View Post
                          Looked at kerning, nothing of any quantity available here. Could not find an on-line supplier either.

                          Ya, mahogany is a really over used word for woods that are not mahogany.

                          Luan is Philippine or sometimes referred to as genuine.

                          Tom
                          Luaun is sometimes called Meranti, but is never referred to as genuine. Philippine Mahogany is sometimes also called "Red" mahogany. They are not Mahogany.

                          There is some Honduran mahogany, which is sometimes called "genuine" mahogany, and that is the last of the American Mahogany, the only stuff left. There is some plantation grown, but it's expensive and hard to get. Khaya and Sapele are Mahogany, but have quite a different look than American Mahogany (genuine, true, what everything was made out of before the trees were gone).

                          They probably want Meranti/Luaun/Philippine "Mahogany" (there are a lot of similar trees over there- they aren't Mahogany, not in the Mahogany family, but the wood is similar-ish, although not nearly as nice to work with). Luaun was called "Philippine Mahogany" as a sales pitch way back when- to give people an idea of what the wood looked like, not to claim it was a Mahogany. People are relatively stupid and have a tendency to think that what an advertisement says has some truth to it- this is a "truth" that has stuck around a lot longer than the people who thought up the sales pitch.

                          Soo.... I wouldn't worry about going with the African Mahogany, stick with the Asian (Philippine) stuff. It's cheaper, easier to get ahold of.

                          Apitone is nice, but I've only used it for Crab Decking on fishing boats.

                          Edensaw seems to have pretty good lines on all of the woods mentioned, although it may take a little time.
                          http://www.lavrans.com

                          "He uses statistics as a drunken man uses lamp posts; for support rather than illumination." -Andrew Lang

                          Comment


                          • #14
                            Re: A couple of doors

                            You're correct the Hounduran is the genuine.

                            The biggest problem with all of this is getting the spec changed. It clear states Asian Mahogany.

                            Like I said, I'm leaning towards Sapele.

                            Tom
                            http://chicagocraftsmen.org/2011/06/261.html

                            Check with the AHJ, what we say doesn't matter.

                            Comment


                            • #15
                              Re: A couple of doors

                              Tom, nice work. Rather than debate it to death and pull your hair out, why don't you call the genius who specified "Asian mahogany" and request an actual species, or a specific material from a specific supplier. Don't put yourself in a position to have to defend a choice you make.

                              Comment

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