Milling the Door Frames
Milling the components for the door frames was probably the most challenging. Since there are 20 doors, milling had to be done for 80 pieces (plus a few extra for testing purposes). They all had to be 2 1/4 inches wide and 5/8 inches thick. Depending on which door they were for, the length varied. Then, the router was used for tongue and groove, as shown in this picture.
Cutting the lumber down to size
The first step was to take the 10 foot planks of Maple wood and cut them down to manageable sizes. The sizes range from 16 to 48 inches long.
Using the planer to mill the pieces down to size
Lumber cannot be planed down to the finished size in just one pass. It is too hard on the planer and the resulting piece would not be smooth. So, it takes several passes through the planer to get to the desired height and width.
The planing process involves placing all the pieces on one table on one side of the planer, adjusting the planer to the first setting, run all the pieces through the planer and set them on another table. Then adjust the planer to the next setting, move the pieces back to the starting place and run them through the planer again. This is repeated several times until the desired size of 2 1/4 inches wide and 5/8 inches thick is reached.
Use a coping sled to cut the tongue into each piece of the top and bottom for the door frame otherwise known as the "rail".
Each piece of door frame rail is placed in the coping jig, run past the router bit which cuts the tongue, then flipped around to cut the tongue on the other end.
Routing a groove
