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Sunday, December 20, 2015

Cabinet Face Frames, Doors and Hardware

Here is the latest on cabinet face frame experiments. This is port side of the forward salon.

The main panel is khaya veneered plywood with maple horizontal inlays above and below the cabinet doors. The cabinet doors are inset with fully concealed hinges. Latches are push button locking types.

This idea includes a grille spanning from above the cabinet doors to the underside of the side decks. The grille is not just decorative as it provides ventilation from behind the cabinet (non-ventilated spaces are always to be avoided on a boat if possible). In the case of the port side, the most forward end of the grille is also the exhaust duct for the future air conditioning system. The grille can be removed to gain access to electrical running along the deck underside.

Mistakes were made with this construction. The main panel cutouts went pretty well, except that, in order to keep the plywood grain vertical, the face panels had to be cut as two pieces, as the length is greater than 48 inches. With most plywood, the grain runs along the longest edge. The final construction will be a one piece cutout, which requires special ordered plywood, with grain running parallel to the short side.

Back side of grille machined from maple. Lots of little tear-out "whiskers" in there.

The grille construction was disastrous as I did not have fences setup correctly on the router table. But that didn't matter as in the end the maple had lots of tear-out, even with new sharp bits. I suppose this is a characteristic of soft maple. It just does not machine well.

So this rules out maple as a contrasting wood, leaving alder as the next (and last?) choice. Alder has a somewhat similar color and grain to that of maple.

Next experiment is to machine a grille from alder, followed by some finish varnish (may try a few more brands).
Face frame without doors or grille

Face frame with doors, no grille

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