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Shaper questions for doors

9/19/18       
Jeff

Hey all, I have bought most of my doors over the years, or relied on others to build them, now I decided I want to get proficient at building them myself.
A few questions I had are, what speed should the head be running at? What is a good coping sled or is it easier to make one?
Do you stack your two sets of door cutters or swap them out for each process as I only have 1 shaper.
I read on here about an after market digital readout, are they good, worth getting?
Lastly any good books or videos that you recommend?
I am not a total newbie at this, I have built them before, in the past I run the styles first with the power feed and then run the rails with a coping sled, but I am looking for tricks from the people who do it all day as I want to be good and efficient at doing it.

9/19/18       #2: Shaper questions for doors ...
rich c.

You'll have to say what diameter tooling you have before a speed can be determined.

9/19/18       #3: Shaper questions for doors ...
Larry Schweitzer

You don't even need a read out to use stacked tooling. Just make yourself a setup jig, preferably out of metal. Making it adjustable with a locking screw is a good idea. Same goes for setting the fence. Make a setup jig that drops into the miter slot. Dirt simple. Same goes for cutting rails to length. Make a stop block the length that you need to take off the outside size of the door. Set the saw fence to the outside size and put the spacer block in to cut the rails to length. No calculations required.

9/19/18       #4: Shaper questions for doors ...
Leo G Member

If you're making more than a couple of doors at a time you are going to get tired of 1 shaper pretty quick. I have 3, cope, stick and panel. I have my cutters by the same company and so far I can swap them out and the only thing I need to do is raise or lower the cutter. If I didn't do a balanced shaker I wouldn't even need to do that.

But, since you only have the one, stacking the cutters is one way to go. The 3rd party digital readouts work well, I have a couple of Wixey's.

If you went with equal diameter cutters you might not even need to stack them. You can swap them out without changing the fence or height of the spindle. Or at worse figure out what shims you need where to avoid moving the height.

I do a destructive cut on my stick (1/16") so I can run the sawed edge against the fence and end up with a nice milled edge. I also do a destructive cut for my cope (1/64"). This way if there is any small out of squareness it is corrected. Very important to get square doors.

This is tough to do with a stacked system or single shaper. Good luck to ya.

9/24/18       #5: Shaper questions for doors ...
RyanB Member

Website: http://www.premiercustomwoodworks.com

I build all my own doors and I have for the last 17 years. All are done on a single 1 1/4" General Shaper. The doors I am building I not able to buy as more and more I am into rustic material that no cabinet doors shops carry or they don't have anything close to matching! I typically will run 50-75 doors/drawers/gables in a run and it takes be usually a day for machining that amount. I made my own sled this past spring and its been a godsend and I don't know how I ever did without it! It does all my copes and also I use it for cutting the ends of my raised panels that are 20" or narrower instead of running them thru flat on the table because. I also built a nice door clamp this past winter at the same time as the sled and its saved me a ton of time. I did 278 doors, drawerfronts and gables and start to finish including maching and clamping was 4 days!!!! Average rate I was making for that run was $850/hr!!!! My previous glue up time for that many doors would have been a minimum of 6days...the new clamp was two days!

This is the first time posting on the forum in at least 6yrs so don't be supprised if I don't answer back right away if you have any questions...I will deffinatly try though!
Ryan


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9/24/18       #6: Shaper questions for doors ...
RyanB Member

Sorry for posting duplicate pictures in my previous post


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9/24/18       #7: Shaper questions for doors ...
Larry Schweitzer

Nice sled. What provision do you have for preventing chip out?

9/24/18       #8: Shaper questions for doors ...
RyanB Member

I run an aux screw on 3/4" thick fence. With both sides installed I get 20.25" inside to play with

9/25/18       #9: Shaper questions for doors ...
Alex Member

Website: https://rangate.com

Hey Jeff,

I work for Rangate (door/window shaper tooling is what we're best known for), so I talk to people in your situation pretty regularly. Like Leo said, using a set with the same inside diameter is the easiest way to do doors with a single shaper, since you're simplifying the adjustments going between tenoning and profiling cutters.

We have a program called CutterShare which we basically created exactly for your situation that I think would be worth looking at if you haven't tooled up yet. It would let you get our door set for way less than buying, plus you'd be working with the best tools available from the jump. (Obviously I am biased, but if you ask around about us, you'll hear the same thing). For something like doors where there's a performance component, it's definitely worth it to use good insert tooling. A brazed set is likely not going to match the profile to the counterprofile well enough for an exterior door after it gets sharpened.

A couple tips on the build process:

- Running the copes first will give you a better fit and finish. That way, if you get some blowout going cross grain, it doesn't really matter, since it gets removed when you do the profiling.

- When you do the profiling, offset the outfeed fence back 1mm to make sure you are taking a full cut.

We have a good video guide to the door shaping process here: https://www.youtube.com/watch?v=-XsU39Wak_o

Anyway helping people get up and running doing doors on the shaper is really what we do, so if you want to do a deep dive on it just send me an email and I'd be happy to talk.


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CutterShare Door Set

10/13/18       #10: Shaper questions for doors ...
jeff

Rich,
Sorry I typed this and it never posted.
I would say the few cutters I have so far are 4-6 inches in diameter. thanks

10/13/18       #11: Shaper questions for doors ...
Larry Schweitzer

All else being equal, the larger the cutter the better the cut. The same kind of goes for the shaper.


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