Making Interior Doors

leakygoose

Any tips/techniques,router bit recommendations that I can use ,please let me know.
Do to the economics ,I think I'm going to have to make the 5 doors I need for my own basement thats getting close to the finishing stage .
Being a finish carpenter for over 30 years I've made every kind of door known to man ,cabinet wise but not not 6 panel 1 3/8 interior's. I prefer router bits to the shaper [mine is under powered] .
I have a barn full of walnut and intend to use it for all the trim and doors .
Vanity is done [walnut] curved railing,newel post ,starter step ,done [walnut] now its time for the doors then the moldings .

Thanks, Mike

cleveman

I made a bunch of 4 panel doors years ago out of white oak. I think they were about 1 3/4" thick.

You can mortise your stiles all the way through to accept the rails, or just groove the stiles to accept about an inch tenon on the rails and the same inch of panel.

I assume you're talking about 6 horizontal panels. I made 4 vertical panels and I think your idea is better.

I used the old mortised in locksets and they turned out very nice.

You should have a much easier time of it working with walnut than I had with that white oak.

Make sure you have a dj-20 or so joiner. You will need a long bed.

For the hinges, I just measured carefully, used a smacker, then routed and chiseled out carefully.

As for the jacks, I put a threshhold in. I would make the jambs and heads, and threshholds if you like, and pre-finish them, then assemble and install the door, then take the door out and mount the jacks, install the door.

You certainly want to finish everything before you hang.

If you don't go with a threshhold, put in a temporary throw-away threshhold to help with the installation, or at least a spacer of some sort across the bottom of the jacks.