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TDL Door assembly3/5
I have everything i need in place to produce shaker/square and ovalo/ogee Wood TDL's but what is the easiest way to assemble them?
I've built the door frame they added them in after, didn't work very well. Built the stile rail door and 15 Lite TDL all at the same time and am worried about open time by the time its all lined up and clamped down.
Lots of parts, eh? The shop I learned in a long time ago did not glue the muntins together. We also did not tenon the horizontals in to the stiles. The stiles were crowned to hold the horizontals tight. The coped, tight fitting joints were just tapped together, and held all in place until the glass went in, the day after assembly. Then the stops mitered in, were nailed, and held everything in place.
When we make 15 light or similar divisions, we will rip out the glass rabbets on the muntins, before final rabbets are machined. These pieces are the exact length of the glass opening, so make great spacers during glue up, keeping things in place and spaced properly so you do not have to pull a tape. You do not want to pull a tape to measure anything during glue up. Use a layout stick or spacers cut to lengths.
We will place the vertical muntins (sometimes called "mutts") onto the horizontal muntins onto layout marks, with a bit of glue, and then into the door assembly as it goes together. Then a long clamp or two are placed to clamp the length/height of the door and pull everything up tight. Then a clamp across the top rail and one on the bottom, locking everything in place.
Nowadays we mortise the horizontal muntins (photo), but rarely do the verticals - only if the sticking is square, then there is nothing to keep things together. We offset them in the thickness, so 1/2" tenons will become two 1/4" tenons in the verticals. We will put a dab of glue in place, but it still the glass stops that hold it all solid. The stops need to be tight!
As for the glued assembly, have everything ready: clamps in place, door up off the bench, mallet and tap block, glue and brush, bumpers to protect the stiles from clamp damage, and all the door parts, face up or face down. It is good to have a helper at this point. Two working well together can assemble a door in less than half the time of one. Put away the phones. Allow no visitors.
The photos show a few steps, but none of divided light doors going together.
I have equated door assembly as the logical end of several days of 'foreplay' if you will. It took a while to get here, all is well, so don't interrupt me, I'm going home to the finish! Satisfying work.....