Post 54 in an ongoing series describing the design and construction of a kabukimon, a type of Japanese gate. This is a project for the Museum of Fine Arts in Boston.
I cracked open the other box from Zuani and here’s what I found inside:
The spur cutters are removable, and the other knives cut with a shear:
This tenoning head cuts this twin tenon arrangement, a joint used between the top/bottom rails and the hinge-side stiles on the main doors:
Swapping out the middle disc of that head will allow me to cut the twin tenons for the side door.
The other tenoning head cuts this twin tenon arrangement, a joint used between the top and bottom rails and the hanging stiles on the main doors:
Along with the two tenoning heads I also received a few tools to take the heads apart and remove the insert knives, and a set of shims which will be used when I swap the alternate middle disc into the three-disc head:
Here are the two new heads then, side by side:
In the near future I’ll have to build a cart to hold cutters like these. I saw some good ideas in that regard at Joe Calhoun’s shop in Ouray.
I understand the replacement bore inserts, to allow me to use these heads with a 1.5″ spindle, will be finished tomorrow, then inspected on Wednesday, and shipped Wednesday. Hopefully I’ll have them in my hands by early next week.
This does introduce a bit of a delay into the door making. I nevertheless can make progress on various aspects. Today I re-jointed and planed the main door stiles to dimension, then laid out the mortises and rough cut them:
The layout was a little tricky as the hinge-side stiles, the smaller sections, are not mortised down the middle. Rather, they have mortises on the ends which are equally spaced from a centerline, and mortises elsewhere which are offset to one side. These doors have hanging stiles which are larger sections than the hinge-side stiles because of the way the door’s drawbar is arranged. I had a little head scratching and scratched-out marks are there to be seen from the initial layout.
A closer look, with the hinge side stile above, and hanging stile below:
I would move to cleaning out the mortises next, however I would prefer to wait on that until I have tenoned the rails. So, next week it will be. My goal was to have the three doors made by the end of the month, and I should be able to achieve that even with the delay in obtaining the correct bore insert sleeves.
Tomorrow I can do the same process of layout and rough mortising with the side door stiles. I think this week will involve a bunch of random, ‘tying up loose ends’ sort of work tasks.
Thanks for coming by the Carpentry Way. Next up is post 55