Curved Top Rails
Top and bottom rails can be made
with a curved inner edge, grooved and
moulded to take the door panel. For
this the rail will need to be cut from
wider material with the curved edge
shaped and squared before cutting the
profile.
To cut the curved edge, mark out the
shape on the template material (6mm
MDF or plastic). Cut the curve with a
jigsaw and finish true and square.
Leave extra length at each end to
allow a bearing guided cutter to enter
and leave the curved face smoothly.
Cut the scribed profile at each end of
the rail. Make up a workholder as
shown, using the template to position
the rail. Fit the rail into the
workholder and draw along the
curved edge. Remove the rail and cut
the curve, leaving no more than 3mm
waste material on the waste side of
the line. Cut along the curve with a
jigsaw.
Mount the rail in the workholder and
use a bearing guided flush trimming
cutter to trim the curved face flush to
the template.
With the router disconnected from
the power source, set up the router
table with the profile
scribing
cutter
assembled for
machining the rail and
stile edges. Remove the fence
and fit the clear plastic profiling top
guard and lead-in pin. Fit the rail
into the workholder and rest it flat on
the table. Switch the router on and
feed the work into the cutter, starting
with the lead-in section of the
workholder against the lead-in pin. It
will be necessary to cut the profile to
the full depth in one pass. Therefore
adjust your feed rate to allow waste
to clear and keep the stress on the
cutter as minimal as possible.
to pull the joints tight. Wipe away any
excess glue and check that the door
lies flat and square before leaving to
dry. If the door is to be given a clear
finish, ensure that no traces of glue
are left on the surface. IP
Assembly
Before gluing the joints, assemble
the frame and panel dry. Finish all
surfaces that cannot be sanded
easily after assembly and have sash
cramps and soft packings (to prevent
the cramps marking the wood) ready
to hand. The panels should not be
glued into the groove, but be pinned
with a brass panel pin at the top and
bottom.
Assemble the door using the cramps
FREE
BOOKLET
All profile scribers and panel cutters
are supplied with a 64 page
instruction booklet which features
the constructi