I just noticed that the door epic is not yet complete. I better fix that while I have a chance.
(Why do I have a chance? I am waiting for a new to me computer to arrive so I can get stuck into the online store stuff on a computer that is more up to the task. This one I am using right now is a big box with a 1.1Ghz Celeron, 512M of ram and all the rest of the trimmings. Quite a unit in it’s time (fastest Celeron available when I bought it, and scarce at that time due to it’s newness.) but now, it’s very much ho-hum. The problem is that doing the e-store stuff requires me to set up a virtual server in this box AND run a web browser while shrugging off two kids who want to watch things to make them laugh (if the puter is off, they don’t care) all at the same time, and it just doesn’t work.
So today I ordered another computer.
It’s a notebook sized computer, but it has a 2.4GHz Celeron processor and all the rest of it.
The worst part of it all is that when I built up this computer I am using now, I didn’t get much change from $2000, if I got any at all. This new one is twice as fast and a notebook and I am not getting change from $200.
Doncha just lurve technology?
It’s more than I needed, but it was a case of buy a unit comparable to this one or spend a little more and have a bit more go or spend just a little more for more go, etc, etc. The one I got was at the point where getting much more meant shelling out more money which I don’t really have.
Oh yeah, this computer episode made me visit computer stores and pay attention and at the same time gave me an evil idea with regards to a catalogue for our little store. You will love it, provided we get to that level in business…
On to the doors!)
Last time out I mentioned a material that is, I think, without compare as a core material for torsion boxes. But as I have not used it, I won’t mention it again. What we need to do now is get the door together.
The panels were made slightly oversize so they could be trimmed down after they were all assembled to make sure they were square and straight of which they were neither. To get them right, off to the jointer.
Once they were all straight edge-wise, slightly undersize and the sides square to each other, it was a simple case of running around the outside with a rabbeting bit in the router. I got the tongue so that it was a slip fit to the rails and stiles of the door as much as possible, but on items of this scale, it’s difficult to be absolutely precise. A little trimming here and there with a shoulder plane got the panels to be a good fit that would glue into the frames well and add strength.
Another point to consider on projects of this scale is the glue up. The parts count on these door was 2 stiles, 4 rails and 3 panels. A total of 8 large frame joints and 12 tongue in groove joints for the panels. A lot of gluing area and simply getting the glue on takes a long time, let alone getting it all together tight, flat and square.
Choosing your glue wisely is the trick.
Ideally a slow setting epoxy would be best. It will give you ample time to apply the glue and the glue itself will allow for slightly looser joints and will add a significant measure of adjustability. Sometimes the ‘slipperyness’ of epoxy is a pain, in this case it’s a blessing.
But I used plain old white glue because at that time, epoxy I have would not cure due to the cold where white glue would.
It was a mistake, but one that turned out ok in the end. If you are as foolish as me and use a glue that doesn’t allow enough time to manipulate all the parts, make sure you have plenty of strong clamps and a really big dead-blow hammer. Also make sure you run through the process before hand and have everything right there or you will make a mess of it.
As it was, there were a few small gaps, but nothing easy to find (and in the finished door, I couldn’t find them) and the door was not as ‘nice’ as I would have liked it to be at this stage.
One thing was certain however.
I had saved a heck of a lot of weight and the door was very, very strong.
And that’s all I really needed.
Next time, plugging up those big holes.
Stu.
