Plywood Door for Glass

The router really came into play for this small job. I began by using a piece of ply 10" larger than the final size. I clamped a border on the plywood's face for edge of the router's base plate to run against in order to plunge cut a rectangle for the glass.

I cut three times at 1/4" increased depths to finally cut all the way through.

Before I cut a corresponding, slightly larger rectangle on the back to create a shoulder for the glass to sit inside, I eased the front side's edge first (see above photo). I needed a square inside edge for the router bit's roller bearing to sit against. I used a quarter round bit, set at the right depth to mimic the existing door's profiles. Now I can cut the back side (1/2" larger rectangle).

I cut the plywood to final size and routed it's outside edge in the same manner... once again using the square outside edge for the bit's bearing to roll on.

Now I can back-cut the perimeter for the 3/8ths over-lay profile. First I made a 15 degree and 3/8ths deep cut about a half inch in from all four sides.

Then I set the table saws blade at 90 again and cut into the very edge to complete the shoulder.

Here's what the back of the door looks like...

Here's a comparison of the existing and new door...

I made some small quarter round molding (from solid oak) to retain the glass. Now, it's all ready to hand to the finisher. He says he can hide the laminations you'd see on the edge (plywood). It helps that the stain is relatively dark.

Russell Hudson
Hudson Cabinetmaking, Inc.