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| Building a T&G Door |
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| Written by Charley | |
| Monday, 24 May 2004 | |
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This was one of the first things I tried when I got my router table. A simple, easy to make tongue and groove door. All it requires is a groove along the rails and stiles, 4 tongues (tenons) on the rails and then either a raised or flat panel. Like with every bit of woodwork I do, big or small, I like to start with a quick plan and cutting list which should stop mistakes when cutting the pieces to length. The tongues (tenons) are 10mm long so when working out the measurements for the width of the door you take the width of the opening -in my case it's 230mm- then take off the width of the stiles,( I used 40mm stock so I took off 80mm) then add the length of the tongues each side -so I added 20mm - which gives a final measurement of 170mm. That's how long the rails need to be and is also the width of the panel.  (click photo to enlarge) Once you've worked out the measurements of the rails, stiles and panel you can start cutting everything to their final length. I've set up a stop block on the mitresaw, this is especially useful if you have more than one door to make.  (click photo to enlarge) That's the two rails and two stiles cut.  (click photo to enlarge) Lay the rails and stiles out on a flat surface. Decide which faces are better (which ones you want showing). Once you're happy, mark the face sides and edges and then at each joint do reference lines so you can get the pieces in the same order at glue up.  (click photo to enlarge) Take one of the rails and on the end make a mark 11mm from the edge using a pencil and ruler. This will be the depth of the groove. I know the tongue is going to be 10mm but the extra 1mm will allow room for glue and movement for the panel.  (click photo to enlarge) Over to the router table - and with it unplugged from the mains insert a 6mm cutter. By eye adjust the fence till the router bit is centered to the thickness of the rail. Set the height of the bit half way to the pencil mark you made in the step above (about 6mm).  (click photo to enlarge) Plug the router back in and start running all the rails and stiles through. You could set up a feather board to keep the pieces firmly against the fence but as I was only doing a quick sample I didn't bother. Once you run the piece through on one face turn it around and run it along the other face making sure the groove you have just cut is still facing down. This will create a perfectly centered groove. I used a push stick to aid the pieces through and to keep my fingers away from the router bit and I wore a P2 dust mask.  (click photo to enlarge) Once you've run all the pieces through, raise the router bit to the final depth (11mm) and then repeat the step above. Afterwards you should be left with perfectly centered grooves in the rails and stiles. If you are using a hardwood for the rails and stiles, then I would cut the groove in at least three passes. Raising the router bit higher, taking a little amount off at a time until you reach the final height.  (click photo to enlarge) The next job is to cut the tongues (tenons) Take one of the rails and make a mark 10mm from the end using a pencil and ruler.  (click photo to enlarge) Go back to the router table. Make sure it's unplugged from the mains and then using the rail piece you just marked 10mm and a square, set up the fence so it's 10mm from the edge of the router bit. Now it would make sense to change the router bit with a wider bit but as I only had two rails to rout I didn't change bits, I just took multiple passes.  (click photo to enlarge) Go to page2.... |
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