Door subcontractor wanted

mbcabinetmaker · Post by **mbcabinetmaker** » Sun Dec 20, 2009 11:06 am

This is my next project. Anyone interested in building these fancy maple glass mullion doors?

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JPG · Post by **JPG** » Sun Dec 20, 2009 11:42 am

NO!:eek: But that would make an interesting project for 'Show n Tell' on this forum!;)

charlese · Post by **charlese** » Sun Dec 20, 2009 2:44 pm

Are they going to be false mullions? Or will they hold the glass? Yes! always interested!:) I ran across the neatest easy method to make mullions (to hold glass) a while back.

45º mullions should be do-able.

mbcabinetmaker · Post by **mbcabinetmaker** » Sun Dec 20, 2009 3:11 pm

What method did you use Chuck? I would prefer to have one solid piece of glass but that might not be feasible.

charlese · Post by **charlese** » Sun Dec 20, 2009 3:50 pm

The mullions are actually two pieces each. A top piece and a lower piece. The lower pieces are squares, cut to length. The upper pieces are shaped using a router table for both the top shape and the copes.

The lower pieces are inserted into the frame and then the upper pieces are glued to the lower pieces. (Of course the rabbet in the frame must be made the same depth and the square size as the bottom of the mullions)

After coping the uppers to length, it seems a minor operation to cut 45º miters on both top and bottom pieces. However, (didn't think of this earlier) there will have to be miter copes cut into the upper pieces.

In my frame (shown above) the horizontal pieces are fit to the frame and the vertical pieces fit later. With the angular mullions, it seems one of the diagonals should be fit to the frame and the other two (shorter) pieces fit to the diagonals. Then glass installed from the back side.

To make false (floating) mullions just use the top pieces.

With all of your experience and abilities, this should be a snap! Maybe time consuming, but a snap.

I've forgotten the sizes of the router bits, but they are two different sizes. Something like a 1/4" roundover and a 1/2" cope

or vice versa.

mickyd · Post by **mickyd** » Sun Dec 20, 2009 4:28 pm

[quote="JPG40504"]NO!:eek: But that would make an interesting project for 'Show n Tell' on this forum!]
I agree with jpg. Lots of pics would be nice!!! Very interesting project.

mbcabinetmaker · Post by **mbcabinetmaker** » Sun Dec 20, 2009 6:08 pm

Thanks Chuck I know what you are talking about. I saw something similar in a wood working magazine some time back. The double copes in the corners will be the real fun especially trying to keep everything to length.

I will keep you all posted if the price is not a deal breaker.