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post #1 of 11 (permalink) Old 02-07-2010, 06:57 AM Thread Starter
 
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Default Panel Doors

Hi
I am resonably DIY proficient, I have a router but have used it very little.
I have a job I want to do on a panelled outside door. I would like to cut out the top panels and put some glass in with a beaded frame. This is to have a little more daylight in my Hall. I suspect a router would be perfect for cutting these panels out accurately but I am unsure how to go about it and do not want to make a mess of it. What bit should I use, what guide or template should I use or make?
Thanks in anticipation....................
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post #2 of 11 (permalink) Old 02-07-2010, 12:00 PM
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I would make a rough cut (plunge cut) using a hand held circular saw. Then I would clamp on guide strips to guide the router with a straight bit to clean it up.

Add 1/4 round inside and out to hold the glass in place.

Keep in mind that almost all building codes prohibit glass in doors if it is not safety glass. In this case I would consider 1/2" wired glass, safety glass, or tempered glass.

The glass panels will be large enough to allow a thief easy entry. The thicker glass (or 1/2" thick acrylic) will maintain security to a degree.

Note: 3/4" acrylic is bullet proof and stronger than your door itself.
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post #3 of 11 (permalink) Old 02-07-2010, 06:05 PM
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Quote:
Originally Posted by Paul A View Post
Hi
I am resonably DIY proficient, I have a router but have used it very little.
I have a job I want to do on a panelled outside door. I would like to cut out the top panels and put some glass in with a beaded frame. This is to have a little more daylight in my Hall. I suspect a router would be perfect for cutting these panels out accurately but I am unsure how to go about it and do not want to make a mess of it. What bit should I use, what guide or template should I use or make?
Thanks in anticipation....................
Paul Obviously you are able to see the size of the cut out on the inserted panels. Measure the size (and select a template guide and straight cutter) add to the size the difference between the Guide and the Cutter and make a simple frame from various pieces of say MDF. Clamp the frame to the back of the door and rout to the depth of the back of the panel and it should fall out. Note; To find the depth of the groove the panel is situated in when calculating the cut-out, have a look at the top of the door.
Tom
(Template Tom)
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post #4 of 11 (permalink) Old 02-07-2010, 07:37 PM
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Hi Paul

Note the router bit set below at the right price that you can use on your router TABLE.
Be sure to see the same web page how you can use the set..

3pc 1/2" SH Window Sash/Glass Door R&S Router Bit Set - eBay (item 140381100936 end time Feb-12-10 19:39:42 PST)

=====




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Last edited by bobj3; 02-07-2010 at 08:20 PM.
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post #5 of 11 (permalink) Old 02-07-2010, 08:21 PM
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It seems I need to pay attention to what you write. I searched and searched all over looking for cheaper Rail and Stile bits. Never found these in my ebay or google searches. Haven't checked yet to see if any of them are 1/4" shank. I sent the search link to She who buys things.


Paul, if you have used the router as little as I have I would recommend running the template over some thing else cheap first and see if it makes exactly what you want. Then make any adjustments needed and either go for it or make another test run.

Test runs I am getting good at, actual finished product not so much yet.
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post #6 of 11 (permalink) Old 02-07-2010, 08:35 PM
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Hi Derek

They do have 1/4" shank items but most of the are smaller in diam. on the cutters but they have a place in the shop tools also..when you want the lighter look to a project or if all you have it a 1/4" router..
I'm not a real big fan of the 1/4" shank cutters when you get into the R & S stuff..but they do the job..

here's just one of them.
2 pc 1/4" SH Cove Panel & Rev. Class R&S Router Bit Set - eBay (item 130364400967 end time Feb-10-10 16:16:17 PST)

========


Quote:
Originally Posted by DerekO View Post
It seems I need to pay attention to what you write. I searched and searched all over looking for cheaper Rail and Stile bits. Never found these in my ebay or google searches. Haven't checked yet to see if any of them are 1/4" shank. I sent the search link to She who buys things.


Paul, if you have used the router as little as I have I would recommend running the template over some thing else cheap first and see if it makes exactly what you want. Then make any adjustments needed and either go for it or make another test run.

Test runs I am getting good at, actual finished product not so much yet.



"It's fine to disagree with other members as long as you respect their opinions"

Marc Sommerfeld Tools ,Videos
http://www.youtube.com/channel/UCT-n...RWaEpMA/videos

Find all threads started by bobj3
http://www.routerforums.com/search.php?searchid=944097


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post #7 of 11 (permalink) Old 02-07-2010, 08:38 PM
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Quote:
Originally Posted by DerekO View Post
It seems I need to pay attention to what you write. I searched and searched all over looking for cheaper Rail and Stile bits. Never found these in my ebay or google searches. Haven't checked yet to see if any of them are 1/4" shank. I sent the search link to She who buys things.


Paul, if you have used the router as little as I have I would recommend running the template over some thing else cheap first and see if it makes exactly what you want. Then make any adjustments needed and either go for it or make another test run.

Test runs I am getting good at, actual finished product not so much yet.

Derek, The bits Bob linked to are 1/2" shank.

James
Whittier, CA.

Have a nice & safe day!
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post #8 of 11 (permalink) Old 02-07-2010, 09:54 PM
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Thank you, both. I sent Her the link to the 1/4" ones.

The next router is going to be 1/2" plunge. Brand unknown, but I want one porter cable router kit with two bases that I have seen several times while searching for various router stuff. That will have to wait a few months after all that has been bought since Christmas and is planned to be bought (dust collector). Would really like to upgrade the table router to something higher than 1.5hp or 1.75hp and 1/2" too.
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post #9 of 11 (permalink) Old 02-07-2010, 10:55 PM
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Hi James

Read the link one more time ( 1/4" shank)

====

Quote:
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Derek, The bits Bob linked to are 1/2" shank.



"It's fine to disagree with other members as long as you respect their opinions"

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post #10 of 11 (permalink) Old 02-08-2010, 02:03 AM
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Hello Paul, and welcome to the forums. Glad to have you join us.




Dave
the "Doctor"

In woodworking there is no scrap, only firewood.



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