andyb
07-11-2010, 11:56 AM
Here is a door panel, rails and stiles that I just cut for a customer. I had to reproduce a door that its mate hit the road at 70 mph and burst into a hundred pieces. The customer supplied the material. The original cabinet is a hand-carved antique that came from India. The cabinet is made out of Indian Rosewood. The customer said that the cheapest that he could find the Indian Rosewood is $35+ bft and is hard to find in the area. The customer found a substitute (can’t remember the name) for $17 bft but when he tried to stain it to match the original piece he just couldn't get it to match. The only wood that he could find to match the stain close enough was white oak. The texture of the white oak is somewhat the same but the color a whole lot lighter. He is having me cut 2 doors, along with the design in the rails and stiles.
I created the sunburst and the raised panel. The design in the middle is just v-carved with a 60 degree v-bit of the original design that I traced in Aspire. The flourish was created by James Booth and as usual he did a good job. The customer is going to do some hand carving around the flourish and sunburst to give it a hand carved look to match the rest of the cabinet. I plan to deliver it to the customer in the morning.
Material: White Oak
Panel Size: 21 ¾” x 13 ¾”
V-Carve: 60 degree v-bit, 14000 @ 3 ips and about 2 minutes to cut
Roughing Cut: 3/8” endmill, 16000 rpm 3/8” per pass @ 5 ips and 45 minutes to cut
Finish Cut: 3/16” ballnose, 16000 rpm @ 2.5 ips, Raster cut along the grain, 3 hrs and 10 minutes to cut
Cutout: ¼” endmill, 14000 rpm @ 3 ips and less than a minute to cut
Rails and Stiles Size: Rails 26 7/8” x 3”, Stiles 20” x 3” extra length to allow for tenons.
Rails Finish Cut: 1/8” ballnose @ 2.5 ips. 20 minutes per board, 2 boards, 2 design per board
Stiles Finish Cut: 1/8” ballnose @ 2.5 ips. 30 minutes per 1 board, 4 designs per board
After thoughts:
Carving the panel in white oak left a lot of fuzzes on the end-grain. Since the customer is going to do some sanding and hand-carving, I wasn’t that worried about some of the tool marks left from the 3/16” bit. If I had to do this for a customer that was just going to do a little sanding I would use a 1/8” ballnose to get a little more detail and maybe slow the cut speed down. The drawback to using the 1/8” ballnose is that it would increase the cut time to over 5 hrs per panel. Overall, I’m happy with the way everything came out. I showed it to my landlord, cabinet shop owner and customer. He mind went wild. Now he is wanting me to do some carved cabinet doors for him as samples.
I'll have the customer get pictures of the finished project to post later.
Stay tuned, the customer has another project to cut a raised design is a upper and lower panel. More designs created by James Booth. We are just waiting on the homeowners go ahead.
I created the sunburst and the raised panel. The design in the middle is just v-carved with a 60 degree v-bit of the original design that I traced in Aspire. The flourish was created by James Booth and as usual he did a good job. The customer is going to do some hand carving around the flourish and sunburst to give it a hand carved look to match the rest of the cabinet. I plan to deliver it to the customer in the morning.
Material: White Oak
Panel Size: 21 ¾” x 13 ¾”
V-Carve: 60 degree v-bit, 14000 @ 3 ips and about 2 minutes to cut
Roughing Cut: 3/8” endmill, 16000 rpm 3/8” per pass @ 5 ips and 45 minutes to cut
Finish Cut: 3/16” ballnose, 16000 rpm @ 2.5 ips, Raster cut along the grain, 3 hrs and 10 minutes to cut
Cutout: ¼” endmill, 14000 rpm @ 3 ips and less than a minute to cut
Rails and Stiles Size: Rails 26 7/8” x 3”, Stiles 20” x 3” extra length to allow for tenons.
Rails Finish Cut: 1/8” ballnose @ 2.5 ips. 20 minutes per board, 2 boards, 2 design per board
Stiles Finish Cut: 1/8” ballnose @ 2.5 ips. 30 minutes per 1 board, 4 designs per board
After thoughts:
Carving the panel in white oak left a lot of fuzzes on the end-grain. Since the customer is going to do some sanding and hand-carving, I wasn’t that worried about some of the tool marks left from the 3/16” bit. If I had to do this for a customer that was just going to do a little sanding I would use a 1/8” ballnose to get a little more detail and maybe slow the cut speed down. The drawback to using the 1/8” ballnose is that it would increase the cut time to over 5 hrs per panel. Overall, I’m happy with the way everything came out. I showed it to my landlord, cabinet shop owner and customer. He mind went wild. Now he is wanting me to do some carved cabinet doors for him as samples.
I'll have the customer get pictures of the finished project to post later.
Stay tuned, the customer has another project to cut a raised design is a upper and lower panel. More designs created by James Booth. We are just waiting on the homeowners go ahead.