Pictures Of Work-in-Progress

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	This is the Entrance (under construction) to the Uhlmann Residence in Little River, California
	2-1/2" thick planks of Genuine Mahogany .... about to be "cut up"
	The planks of Mahogany are then sawn into many pieces for a pair of Entrance Doors
	The boards are then jointed straight and flat on one face before they go through the thickness planer
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	The 20" Planer knives are sharpened before planing the Genuine Mahogany
	The old knives are then replaced with the newly sharpened set
	After being flatten on one face,each board is surfaced and left oversized.
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	Still oversized in thickness and width the boards are stacked to "rest" and settle before further surfacing and machining
	The custom shaper cutters needed a little adjustment and were sent off and reground for a better match! This is cut is called the "sticking" and is the detail that you see when viewing the molding on a door.
	This is the female set of the shaper cutters .... called the "coping" The cutters have to be aligned perfectly and mate with precision. These are practice pieces that are run and re-run many times until they mate perfectly flush and true
	Next I made a jig to handle "coping" such a short Mullion. This is a coped "practice" mullion, actual size of only 3-1/4" long Next I'll make a jig to shape the molded sides There are 24 short mullions in each door
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	Then a "Heat Wave" visited our beautiful Coast...... ........ soooo, I took the morning off to play with my grandson in his new swimming pool. We had a BLAST !!
	Next .... all the pieces that have "settled" for at least 10 days are re-straightened, planed to a finish thickness of 2", and re-jointed for a square edge
	All the 68 pieces are then cut to their final length and width
	The pieces for the 2 doors are then sorted for color and grain. Then they are laid-out and marked for mortising and doweling. The cross pieces show the final layout of the horizontal mullions
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	Drilling the long "mullions" on top and bottom and then the sides ..... 48 in all .... per door !
	Then each mullion is shaped on each end This is called "coping". All the mullions were then coped to fit in the door
	Then the tops (2) and bottoms (2) are coped ...... that is the female end of each piece ...... The ends will mate to the sides that are shaped next.
	Then the tops and sides are shaped with "sticking" .... that is the male edge of each piece .....
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	All of the "short" mullions (48 pcs) are the bored for dowels
	These are genuine Mahogany dowels that we make in our shop from the same wood the doors are made from.
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Mace & Lee