Building a Custom Door with Trapezoid Glass Accents

This project started out being a built-in bookshelf, but the client decided to move the bookshelf away from the wall to create a small room behind it to be used as a meditation and message area when taking a break from work.

As with almost every project, I started out rough-cutting the parts to the general size, usually just a little bigger than needed, so I could let the wood move before milling and joining it to the final thickness and size.

I used my shop-made tapering jig to cut the top and bottom rails to start the angle for the trapezoid-shaped glass accents.  I have been thinking about getting the micro jig version.  If anybody has one, please let me know what you think of it in the comments below.

Once I had the angle figured out and the space divided into three equal parts, I cut the middle rails to fit using my Incra HD1000.  

I used the Domino XL with the largest tenons available for the joinery.  I know some purists will have a fit because I used a Domino instead of traditional mortise and tenons, but on a project this size, I needed to build the built-in bookcase as well. I needed a fast and accurate way to finish the job and not hold up the rest of the site construction.

I lost some footage and photos of routing out for the glass panels, but I used a rabbeting bit from Rockler to create a rabbit for the glass to rest in.  I returned and chiseled out the round corners to match the trapezoid angle.  Then, when I install the glass, it will be held in place with glass stop-tacked with brad nails.

The jam is custom-sized to fit the structure of the bookcase.  However, I did plan to use a 1 3/8” standard-thickness door so I could use standard-size hinges and templates.

I used a Porter cable hinge template #59381 to route out the mortises for the hinges on the jamb and door.  This template worked great to be sure everything lined up.    When I was deciding what jig to use for this project, several reviews stated that this jig was inaccurate.  However, I found it to be accurate and worked great.  After using the jig, I think those reviews may be based on user error, not product quality, as there are some details to pay attention to when using this jig.

The Porter Cable Hinge template came with a corner chisel for square hinges.

To route out for the strike plate and mortise for the door latch, I used the Porter cable Strike and latch template #59375.  It was a good thing that this template was plastic, as due to my not paying attention, I was routed into the plastic on more than one occasion.

To drill the hole for the doorknob, I used the standard hole saw kit for boring doors, which is available almost everywhere.

To hold the door on edge, I used a shop-made jig comprising of a 2×4 base and plywood triangle supports screwed to the 2×4.  It was surprisingly stable.

Then when I finish the jamb, I build it around the door to be sure that the reveal was the same all the way around.

And finally stained with the customer’s choice of color and installed on the bookshelf.

If you want to see more completed pictures, order a custom bookshelf or door. Please check out my website for a custom built-in bookcase with a trapezoid door