April 13, 2019
After a light sanding and cleanup, I applied another coat of varnish to the overhead trim pieces.
There were four cabinet doors required in the cabin: One for the opening to the chainlocker; one for a small storage cubby a the forward end of the v-berth; one for a storage area beneath the galley sink; and a final one for the lower galley storage area, against the hull (though this opening required modification in order to fit a cooler within, so I left this door for later).
Concentrating for now on the three doors that were ready for attention, I measured the rough openings and figured out the sizes of the doors needed. These would be simple surface-mount flat-panel doors, built from cherry.
Once I’d determined the overall frame size, I cut the rails and stiles from some 2″ wide stock that I’d earlier ripped for this purpose.
Next, I slotted all the frame pieces to accept the plywood center panels. I used a slot cutting bit in a router for this job, since the slots in the vertical stiles had to end before the ends of the pieces so the slots wouldn’t show through. I didn’t have any fancy setups to make these cuts, so with the slot cutter I had I required two passes to make the slot the proper width for the panels, which was OK for a small quantity of doors like this.
To ease the transition between the frame and panel on the visible side of the door, I clamped the frame pieces tightly together temporarily and routed a chamfer on the edge, which I’d later sand clean and smooth before final assembly. For the moment, I was out of time, so I set the pieces aside for later attention.
Total time billed on this job today: 3.5 hours
0600 Weather observation: 42°, clouds and showers. Forecast for the day: Showers, fog and mostly cloudy, 66°