I had a door style in mind and pre-cut the pieces to prop & clamp in place. That let me see if it’s really what I wanted. YES! Oh-and,
they’ll have chicken-wire too!
Did you figure out what I’m using in lieu of traditional fret-work?
The end brackets that hold a mirror on a dresser!
So here’s how I’m building the doors
The first order of business was to
mesh the face frame material to the fret-work pieces.
All of the parts are just propped and clamped together here, and the top rail is set behind the fret-work.
The doors are put together in a standard way but I did use a pocket screw jig for the joinery. Everything was standard EXCEPT the top rail and the fret-work.
Below is a door completed—showing it from the back side, and with a general break down of the parts.
To best explain how I overcame bringing two disparate parts together, this is how it looks complete –back and front– and then I’ll break it down.
I joined the two parts together (the fret-work & top rail) with a HALF LAP JOINT.
1st -I marked the FACE of each so I would cut the correct sides!
2nd –I set the blade in the table saw to “whittle” away the desired depth.
I don’t have a dado set for the table saw, so a single blade goes much slower. This is just 1 way to achieve the half lap.
The arms that I’m using as fret-work (that used to hold a mirror up on a dresser) had a mortise and tenon joint, so I chose to remove one side of the mortise and the slot that the tenon would have fit into. Hope that makes sense to you.
Next, I reset the depth of the blade to cut the other “half” in the top rail.
Then I glued and clamped the two parts together. You can also see the rails are over-sized so I could cut them down to an exact fit.
While that part was setting up I moved onto the rest of the door frame.
3rd -Beginning with creating the pocket screw holes in all of the rails.
Then I screwed the bottom and center rails to the stiles—and finally, the set-up top rails (with attached fret-work).
And I glued and filled in the pocket holes with plugs for a clean finish.
Here’s a close up of those plugged pocket screw holes.