Making a door

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hi i have just had to replace a pane of glass today in a door with the same curve on top. the bottom and two sides were beads the top one was one solid piece moulded with the top of the door.
 
Just made this out of American White Oak
dcp_1747.jpg

Following the top rail being set out it was cut out on the bandsaw

P1000426.jpg


Then sanded smooth on a sanding block on the spindle
P1000427.jpg

Following this a small rebate block was placed in the spindle with a bearing collar added to the top, the bearing collar being accurately turned on an engineering lathe to give an half inch rebate (i.e. 1" smaller than the rebate block
P1000433.jpg

door10.jpg

the moulding on the opposite side was applied with a bearing router
P1000446.jpg

the beads were laminated by using the spindle as a thicknessing sander
DCP_1769.jpg

then laminated between two pieces of mdf
DCP_1763.jpg

once glued the thicknessing sander was used to clean up and simension to size
DCP_1766.jpg

and subsequently moulded with the router
DCP_1764.jpg

ready for fitting
DCP_1761.jpg

If you need more info re the actual making of the door let me know

(thanks to motownmartin for showing me how to place images in posts)
 
As shown with he rebate block and the turned bearing collar, it works like an extremely large bearing router cutter but the bearing needs to be exactly 1" smaller than the rebate block to cut an 1/2" rebate
P1000428.jpg

door10.jpg
 
looks great. is this a process you use alot making doors?
one thing that i have been wondering for a while now, is the gun stock stiles your door has, how did you cut them exactly?
 
Great to see another Craftsman added to the forum ! That is class work !
 

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