Tuesday, October 23, 2012

Thread: Walnut doors with stained glass inserts - Family Woodworking

Week ending October 21st: (post two of two)

The overall quality of the walnut is quite good, but there are a few knot holes. I deal with these using a mixture of walnut planer shaving, walnut sawdust, and epoxy (QuickCure 5) in steps as shown in the photos below:

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Name:	Kitchen to Dining Room door project 08 -About to mix material used to plug knot holes -small.JPG
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Name:	Kitchen to Dining Room door project 09 -Mixing material used to plug knot holes -small.JPG
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Name:	Kitchen to Dining Room door project 10 -Knot hole has been plugged -small.JPG
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Name:	Kitchen to Dining Room door project 11 -Filled -n knot hole has been sanded -small.JPG
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The mixture dries very hard and can be readily sanded. Once a finishing coat is applied (later), the former hole blends in reasonably well.

The walnut is screwed as well as glued, then the screw holes are plugged with walnut dowels. These are ?manufactured? from cut offs:

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Name:	Kitchen to Dining Room door project 12 -Creating a lot of walnut plugs -small.JPG
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Here, boards are being installed around the door frame:

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Name:	Kitchen to Dining Room door project 13 -Attaching laminated walnut pieces to door frame -small.JPG
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I just noticed when looking at this photo now that I chipped then paint off a couple of tiles when taking off the old molding. Oh well, I still have most of a box of tiles left over from when I applied them about 25 years ago. I expect that I will need to purchase new grout though.

Source: http://familywoodworking.org/forums/showthread.php?28729-Walnut-doors-with-stained-glass-inserts

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