Apr. 1 | Mon.
Sand and prepare the stop trim for installation. This trim is put in place the secure the raised panels.
Process western red cedar sign blanks: Cross-cut, surface, rip to width, process in shaper, epoxy and clamp.
Apr. 2 | Tue.
Sand western red cedar sign blanks.
Build a jig to allow me to make a clean cut through the sapele door, which will later have mail slot hardware installed.
Begin the process of cutting the mail slot into the door: drill four pilot holes, make a rough cut with a jig saw to remove most of the material, then follow up with a flush-trim router bit to give a clean, uniform slot in the door.
Apr. 3 | Wed.
Begin install of the panel trim. Each piece needs to be be mitered and cut very precisely so that the resulting joint is nice and clean. Finished one side of the door.
Apr. 4 | Thu
Continue installation of the panel trim on the opposite side – up to this point, the trim is neither glued or fastened. It must still be loose at this point in order to allow for the installation of the panels.
Trim the raised panels to their finished dimensions and then place them in the door. Then reinstall the pre-cut trim pieces, this time with glue and brad nails.
The process of adding the mail slot had me kind of nervous. Many hours had been invested in preparing the door to this point, so I knew that putting a large hole in the center of it meant that a small mistake could be very costly. Fortunately, I didn’t encounter any issues in doing so.