Wall mounted Plane and Tool Cabinet - Part 3 - External Door

Trimming the edge banding was done with a bearing guided flush trim router bit. However this leaves a radius in the inside of each internal corner that needed removing with a combination of chisels and chisel plane. The chisel plane was also used to flush up to the plywood as sometimes the router bit leaves a few proud edges.

Using a chisel to clear the round corner

Followed up by the chisel plane

The door parts were made next. As I didn;t have enough walnut width for the entire door, this was being made with what I had on my shelves after all, I made a few glue ups. I did use some dark Titebond II rather than the Titebond II shown
on the pictures.

After the glue up these sections were milled to size using the jointer/planer, a rabbet cut for the front panel and again dovetailed/glued.

Woodpeckers and Rockler clamping squares were used
to maintain squareness.

The 18mm (3/4) birch plywood front panel was then cut to size to size and dropped into place. This was not glued in but I drove some stainless screws in and plugged the holes. When dried the plugs were sawn off, the edges of the walnut trued and the next stage of the operation was prepared for.

Walnut plugging the screw holes.

Inside of the door

The hinge has leaves that are 1.2mm (3/64") thick so I had to cut a slight rabbet in one of the door stiles and the face frame of the carcass. To do this I used a Record 778 rabbetting plane. This is definitely the best tool for the job. 

Marking the 1.2mm line on both of the edges.
Once you've started planing you don't know how deep you've gone
so it's always best to work to a line

The 778 in operation. This is a superb plane

The resulting rabbet. Note the ends of the untouched
edge banding can be used to register the hinge in place. 

The hinge was fitted first of all to the carcase whilst on its back. The external door was then propped up to the same level as the carcase face, using whatever handy pieces of scrap I had around, and screwed into place. If everything was square in a perfect world it would meet precisely. However this is not a perfect world so I purposely had made the door slightly oversize so I could plane it flush to the carcase. This planning paid off and I now have a perfectly fitting door.

Door fits perfectly

Stainless steel piano hinge fitted