mulwyk Posted February 15, 2012 Share Posted February 15, 2012 Here's a quick summary of the door building procedure. The picture shows the inside of a typical cabinet door. (1) Make redwood frames. I use simple glue and biscuit joints (yellow carpenters glue and #10 biscuits). Back in the day, I used dowels for these joints, but biscuits are much faster if you buy or have access to a biscuit jointer. The frames are made 3/4" to 1" wider than the door openings. After the glue sets, round over the outside and inside edges on one side (the side that will be visible on the finished door...use a router and 3/8" radius bit. (2) Cut a piece of 1/4" birch plywood and a piece of cane (get cane on eBay). Cut them roughly the same size as the redwood frames. Set the cane aside for a moment. Temporarily nail the plywood panel to the redwood frame. Using a trimming bit in the router, cut the interior hole in the plywood panel (the trim bit will follow the exact shape of the redwood frame). (3) Remove the plywood from the redwood frame. Soak the cane in warm water for an hour or so. Then apply glue to the plywood and the redwood frame and make a sandwich...redwood, cane, plywood. Nail the sandwich together with plenty of 3/4" brads. The cane will tighten as it drys. (4) Finally, cut a recess (rabbitt) around the outside of the door, sand 60, varnish, sand 100, varnish, sand 220, varnish. Hand sanding is fine, tack cloth before varnish. Spar varnish gives the best color. Use self-closing, recessed type hinges. Quote Link to comment Share on other sites More sharing options...
TacomaSue Posted February 16, 2012 Share Posted February 16, 2012 Here's a quick summary of the door building procedure. The picture shows the inside of a typical cabinet door. (1) Make redwood frames. I use simple glue and biscuit joints (yellow carpenters glue and #10 biscuits). Back in the day, I used dowels for these joints, but biscuits are much faster if you buy or have access to a biscuit jointer. The frames are made 3/4" to 1" wider than the door openings. After the glue sets, round over the outside and inside edges on one side (the side that will be visible on the finished door...use a router and 3/8" radius bit. (2) Cut a piece of 1/4" birch plywood and a piece of cane (get cane on eBay). Cut them roughly the same size as the redwood frames. Set the cane aside for a moment. Temporarily nail the plywood panel to the redwood frame. Using a trimming bit in the router, cut the interior hole in the plywood panel (the trim bit will follow the exact shape of the redwood frame). (3) Remove the plywood from the redwood frame. Soak the cane in warm water for an hour or so. Then apply glue to the plywood and the redwood frame and make a sandwich...redwood, cane, plywood. Nail the sandwich together with plenty of 3/4" brads. The cane will tighten as it drys. (4) Finally, cut a recess (rabbitt) around the outside of the door, sand 60, varnish, sand 100, varnish, sand 220, varnish. Hand sanding is fine, tack cloth before varnish. Spar varnish gives the best color. Use self-closing, recessed type hinges. Quote Link to comment Share on other sites More sharing options...
Derek up North Posted February 16, 2012 Share Posted February 16, 2012 Sue is apparently speechless! Quote Link to comment Share on other sites More sharing options...
TacomaSue Posted February 16, 2012 Share Posted February 16, 2012 I am speechless. (Derek --- you were right to make note of it -- doesn't happen often!). The new Sunrader cabinets are exquisite! I also appreciate the very good explanations for constructing them ---- despite the fact that my skill level is not up to this. I found the pictures and explanations inspirational and it gave me ideas for making some of the changes that I want to make in my own cabinets. Last summer, I spent a day on a sail boat looking at how things were kept in place while sailing and thinking about what could be adapted to the motorhome. There were many items like the counter edge that make sense for the little motorhomes. Thanks for sharing your work. Sue Quote Link to comment Share on other sites More sharing options...
bajadulce Posted April 13, 2012 Share Posted April 13, 2012 Been meaning to respond to your topic for quite awhile.Cabinets look fantastic. Redwood doors have a nice contrast with the perforated cane. Nice construction choice. You're quite the craftsman.Countertops look great too. Fiddles make sense if you have passengers (kids especially) and need to have a counter/table while traveling. Quote Link to comment Share on other sites More sharing options...
Stevo Posted January 18, 2013 Share Posted January 18, 2013 Do you have more photos? Not much to see because there is only one little one here. Quote Link to comment Share on other sites More sharing options...
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