On 12/13/2012 9:42 AM, DerbyDad03 wrote:
On Dec 13, 1:25 am, dpb wrote:
On 12/12/2012 6:38 PM, DerbyDad03 wrote:
...

Well, I gotta admit that not one site I've visited, and I just went
through about 6,...

And, if one thinks that all there is to be learned is on the web...

There was/is a whole industry of production woodworking _long_ before
internet was even imagined. There's a "veritable plethora" of
production techniques that were developed before fully automated 4-sided
shapers, etc., and mill shops were mostly handwork instead of CNC
programming.

I was fortunate to have had an instructor when still in HS who had such
experience and then to have been in VA before the last of the mills was
automated and to work w/ some old codgers down there...

There is a lot of stuff on the web, granted, but virtually everything
I've seen is new guys basically inventing on their own or copying
one-of-a-kind stick-by-stick techniques and almost all know nothing of
anything other than a router.

What I outlined turns it from doing a single rail/stile at a time into
making a set for at least a full door at a time if not for multiple doors.

I just finished last year the windows for the barn -- 20 of them suckers
4-lite each. 5/4x8 rough stock so did 4 bottom rails and 5 tops at a
time on the length/end cuts, 4 side rails and 7 muntins.

These are full length tenons w/ coping cut (stub cutter on shaper) so
one starts w/ the length, cut the base tenon w/ double-blade setup on
the TS w/ a tenon jig, then the coping cut. Follow w/ rip the stiles,
cut the mortises, then stick the inner edge.

The muntins are also cut to length in a piece of full-width stock and
the coping cut made across the end as described against the shaper
fence--since it's already square, there's nothing to deal with to keep
them that way. Then one sticks the two outer edges, rips those two
(again the TS fence doesn't have to move as one continues) off and
sticks the other edge of each and then sticking is cut on the two
remaining outside edges and process repeats.

Far, far faster and especially more repeatable than cutting out a piece
at a time as every demo I've seen on the web would have you do...

--

OK, I'm learning and I appreciate the time you've spent explaining the
process.

I'm confused by some verbage...

"Then one sticks the two outer edges, rips those two (again the TS
fence doesn't have to move as one continues) off and sticks the other
edge of each and then sticking is cut on the two remaining outside
edges and process repeats. "

I'm not getting that. I don't know what you mean by "sticks the two
outer edges, rips those two ..."

I guess I don't know what "sticks" means.


get a wide piece. put the correct profile on the 2 outside edges. rip
those pieces off resulting in a narrower piece. repeat until the piece
left is thinner than your target size.