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Interior Four Panel Doors

This page will show a summary of how I constructed the interior four panel doors for my house.
The main floor will be trimmed in Steamed Beech and Yellow Birch and doors will be constructed from Yellow Birch and Curly Yellow Birch.
The upper floor with be trimmed in Ash and the doors will also be constructed in Ash

This page shows two types of joinery for the styles and rails. The first doors were assembled with splined joints and the second method was using Festool's Domino Jointer system. I must say that I do prefer the Dominos system.

To enlarge any of the photos, click on them.



There are four panels in these doors.
The Ash door panels are glued up from solid stock and the Curly yellow birch panels are veneer glued to 1/2 inch plywood as shown in the bottom photo.

 

The following two photos are doors made from curly yellow birch. Expanding these photos by clicking on them will give a better representation of color and figure.

The stock was doubled to make the styles and rails thick enough, then stacked up on the core box and glued three styles at a time.

This is another bench that I made for routing and clamping. It is wider and is on casters so it can be moved out of the way when needed.

This is a test fit to ensure everything is fitting before starting the final glue up

Because of the weight of these doors, I try to do the hinge mortising and lockset operations on the rails before the doors are glued together.

This is the hinge mortising operation

 

The photo to the left is showing the test fit of the panels that are curly yellow birch veneer glued to plywood.

The construction method used on the above doors was to plow a 1/2 inch groove down the rails and styles to accommodate the panels. Then the rails were joined to the styles with  1/2 inch thick splines at the Joints which served as the tenon.

Following are photos of the construction method using Festool's Domino Jointer utilizing loose tenon joinery  


With this type of joinery I used stopped dado's in both the rails and styles


On each side of  the top rail, I used the Domino's narrowest setting to allow for positive positioning of the styles


This is the first section of the sub assembly glue up


This is the entire section glued together


This is the only positive domino on each side of the top rail to locate the styles at the correct alignment for the top, mid and lower rail.


The middle setting for width of the mortise was used for the rest of the dominos to allow for some fudge factor. This is the first test fit for the styles


Now the final assembly begins. The panels are inserted and the dominos where glued into the styles


Everything went together well.

 

 

 

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