We'll use a router table to construct cope-and-stick doors, often found on kitchen cabinets. A flat center panel fits into a groove on the inside edge of a frame, which has interlocking joints cut with two specialized bits. The stick bit cuts the groove in the stiles (vertical pieces of the frame) and in the rails (the horizontal parts). It also cuts the molded edge of the inside of the frame. The cope bit cuts a tenon and negative molding on the rail ends so they nest to the ends of the stiles; the tenons add strength to the joint and plug the grooves on the outside edges of the stiles.

Then we'll focus on making traditional mortise-and-tenon paneled doors, which also have a center panel that fits into a groove on the inside edge of a frame. But the tenon integrates with the thickness of the groove and has a haunch (a stubbed extension) that fills that groove so it's not visible on the top or bottom edges of the door. The dimensions and details are much more customizable: Your door is stronger since the tenons are longer and designed by you. You can have a variety of panels: flat, rabbeted, or raised. You'll use a hand-held router and mortising jig and BARN's vertical hollow-chisel mortiser to cut the mortises and the table saw with a tenoning jig to cut the tenons. You'll use the router table with a raised panel cutter to form the panel and a few hand tools to fine-tune the fit of the parts.

Details

• This class focuses on techniques, not a final project. However, you'll make a door sized to fit the small cabinet for storing table saw blades or sandpaper sheets that's built in Woodworking Basics: Table Saw Techniques.
• All of the bits and jigs used in the class are available in the Woodworking Studio for use on your future projects.

Materials

• A $40 materials fee, included in the class fee, covers everything you need.

Prerequisites

• Woodworking Tool Safety Checkout 1
• Woodworking Tool Safety Checkout 2

Class Policies

• Ages 14 and up are welcome.
• You must wear safety glasses and closed-toe shoes, tie back long hair, and avoid dangling clothing and jewelry. We recommend bringing your own safety glasses.