James Sanders
02-19-2007, 05:36 PM
Ahoy,
It rained today, a lot. In fact, the last couple of weeks we have had a lot of rain, and for that we are thankful. Rain, however, means no boatwork, at least for someone like me whose boat is truly in the open. (I am a purist. When BYYB means Back Yard Yacht Builder, I take that literally. No sir, no garage for me (as if we had a garage.) I have built my boat in the open weather.)
In the meantime, however, since boatbuilding is temporarily out of the question, I decided to work on some doors for a companion. No, I do not mean companionway doors. I mean some French doors for Miss Pat, and another pair for our daughter, Miss Rachel.
I went to an industrial lumberyard as always, expecting to pick up the needed stock and be on my way. It was not to be. The lumberyard had no bananas. I had to search elsewhere, and at last, I found some 8/4 African mahogany. In no time, my truck was loaded down, and I was on my way in the pouring rain.
I got a good buy on the lumberâ a little over $500.00 for what will be 4 mahogany doors is not bad. My billfold is a little thinner now. I just wish I were. Miss Pat and I had looked at some doors at HomeDepot, doors that were part fir, and maybe part plastic. The asking price was $2,500, so I decided not to ask any further.
The horizontal and vertical muntins on the HomeDepot doors looked less than terrible. We just thought we could do better, especially with the muntins, I meanâ why do you want a French door with thin plastic muntins that poorly fit the door frame? I can make muntins that fit just as poorly, have mahogany doors, and pay much, much less.
I set about working on the stock. I had bought some 100 board feet. First, we needed to make the stiles. Because of their length, the stiles would, perhaps, be the most difficult part of the project. Everything had to be straight, absolutely straight and flat. I used the jointer, I used the planer, I used the jointer, I used the planer. When all else failed, I used a handplane. At last, we had stiles that would soon by in style, and the stiles were flat, true, and straight. (My billfold was a little flat by now as well.)
In this photo, maybe you can make out some of the rough stock and perhaps some of the stock we had milled as well. (Everything was rough when we bought the mahogany, very rough.)
All this wood may not look like much. Certainly, the amount of work needed to mill the stock is deceptive, ending up with just 8 boards. We rather like to call them stiles, though. Even so, here is another photo of what the lumber looked like, having been placed in the back of my truckâ
As I came home, Miss Pat was serving dinner, and that was something I did not want to miss out on. So, I abandoned my mahogany stock and went nervously inside, fearing that some knowledgeable soul might see the mahogany, and know that the wood was mahogany, and scamper away with my treasure. Fortunately, most people just saw a wood pile.
I set a few planks down on the tablesaw, planks which would become the stiles for French doors, and stepped back. The beauty of the wood emerged. The stiles looked straight and looked good.
Now, if I can just make the French doors look as good as the wood . . . That's the next challenge. One of these afternoons, the rain will stop, and I will be able to work on the boat again. Such as it is. Such as it was today, and such it will be tomorrow.
It rained today, a lot. In fact, the last couple of weeks we have had a lot of rain, and for that we are thankful. Rain, however, means no boatwork, at least for someone like me whose boat is truly in the open. (I am a purist. When BYYB means Back Yard Yacht Builder, I take that literally. No sir, no garage for me (as if we had a garage.) I have built my boat in the open weather.)
In the meantime, however, since boatbuilding is temporarily out of the question, I decided to work on some doors for a companion. No, I do not mean companionway doors. I mean some French doors for Miss Pat, and another pair for our daughter, Miss Rachel.
I went to an industrial lumberyard as always, expecting to pick up the needed stock and be on my way. It was not to be. The lumberyard had no bananas. I had to search elsewhere, and at last, I found some 8/4 African mahogany. In no time, my truck was loaded down, and I was on my way in the pouring rain.
I got a good buy on the lumberâ a little over $500.00 for what will be 4 mahogany doors is not bad. My billfold is a little thinner now. I just wish I were. Miss Pat and I had looked at some doors at HomeDepot, doors that were part fir, and maybe part plastic. The asking price was $2,500, so I decided not to ask any further.
The horizontal and vertical muntins on the HomeDepot doors looked less than terrible. We just thought we could do better, especially with the muntins, I meanâ why do you want a French door with thin plastic muntins that poorly fit the door frame? I can make muntins that fit just as poorly, have mahogany doors, and pay much, much less.
I set about working on the stock. I had bought some 100 board feet. First, we needed to make the stiles. Because of their length, the stiles would, perhaps, be the most difficult part of the project. Everything had to be straight, absolutely straight and flat. I used the jointer, I used the planer, I used the jointer, I used the planer. When all else failed, I used a handplane. At last, we had stiles that would soon by in style, and the stiles were flat, true, and straight. (My billfold was a little flat by now as well.)
In this photo, maybe you can make out some of the rough stock and perhaps some of the stock we had milled as well. (Everything was rough when we bought the mahogany, very rough.)
All this wood may not look like much. Certainly, the amount of work needed to mill the stock is deceptive, ending up with just 8 boards. We rather like to call them stiles, though. Even so, here is another photo of what the lumber looked like, having been placed in the back of my truckâ
As I came home, Miss Pat was serving dinner, and that was something I did not want to miss out on. So, I abandoned my mahogany stock and went nervously inside, fearing that some knowledgeable soul might see the mahogany, and know that the wood was mahogany, and scamper away with my treasure. Fortunately, most people just saw a wood pile.
I set a few planks down on the tablesaw, planks which would become the stiles for French doors, and stepped back. The beauty of the wood emerged. The stiles looked straight and looked good.
Now, if I can just make the French doors look as good as the wood . . . That's the next challenge. One of these afternoons, the rain will stop, and I will be able to work on the boat again. Such as it is. Such as it was today, and such it will be tomorrow.