Breaking edges on shaker doors
3/29/21
This has been discussed before but I'm wondering if anyone has any new ideas. When we prep shaker doors for finishing we break all the edges with a sanding block. Outside edges are easy, its the inside edge by the panel that is difficult. We put a scrap of laminate on the panel to keep from scratching it with the sandpaper and sand by hand. Everyone in the shop hates doing this and it destroys your fingers. Does anyone have any ideas to speed this up and make it easier? We can order our doors with a 1/16" roundover on the outside edges but there doesn't seems to be an option for the inside edge and there isn't enough space to get a router bit in there.
3/29/21 #2: Breaking edges on shaker doors ...
We use a denibbing sander.
Works well, but obviously an investment in cost and space.
I haven't used them, but the surfprep style thick foam pad sanders seemed like a good option for breaking edges to me.
3/29/21 #3: Breaking edges on shaker doors ...
I struggled with easing the inside edges for a long time. Eventually purchased a single spindle crouch profile sander in brand new condition for $800. Bought a Flex Trim flap sander with 100 grit sanding flaps. It does a great job of easing the outside and inside edge of stiles and rails on shaker doors and drawer fronts.
3/30/21 #4: Breaking edges on shaker doors ...
How about using the Shaker profile that has the slight beveled edge, we do that and because it does not have the 90 corner, sanding is way less involved.
3/30/21 #5: Breaking edges on shaker doors ...
William, I am curious how you use a profile sander to sand the inside edge. Are you doing this after the door is assembled or do you make your own doors and sand prior to assembly? I understand how it would work for the outside edge. I don't have the space for a profile sander but I may be able to rig up some sort of benchtop contraption to do the inside edge.
3/30/21 #6: Breaking edges on shaker doors ...
I got a flap wheel from http://www.flap-wheels.com and modified it to use on a 18v cordless drill, basically a homemade arbor made from a 3/8" bolt. I don't remember what diameter the wheel, approximately 10 inches. Running it at a 45 degree to the edge seemed to work well
3/30/21 #7: Breaking edges on shaker doors ...
Surf prep sander with the foam abrasives is excellent for this application.
3/31/21 #8: Breaking edges on shaker doors ...
Hey Wyatt
I do build my own doors. After glue up I wide belt , RO edge sand and then run thru the profile sanding head. It does both the inside and out side edge of the stile or rail at once. So you have to make 4 passes for each door side. A denibbing sander would be far faster but much more expensive. I have tried the surfprep sander but have had better results with my profile setup. It only takes up about as much floor space as a small shaper.