How to Make Gun Cabinet Doors
- 1). Set the fence of the table saw at 2 inches. Rip two pieces from a 4-foot 1-by-6. Set these aside.
- 2). Set the fence of the table saw on 3-1/2 inches and rip one piece from the remaining 4-foot 1-by-6 lumber. Measure from one end of this piece and make a mark at 20 inches and cut it with the electric miter saw. Repeat this from the other end of the same piece. This will result in two pieces measuring 3-1/2 by 20 inches.
- 3). Set the fence of the table saw at 3/16 inches. Set the blade height at 1/2 inch. Cut one groove down the long edge of the four pieces. Next, turn the pieces around to cut another groove on the same edge. This should result in a groove that is 3/8 inches wide and 1/2-inch deep.
- 4). Set the fence of the table saw at 1/2 inch over the blade. Set the height of the blade on 3/16 inch. Set the end of the 3-1/2-inch pieces against the fence and cut it across the grain. Repeat this for both ends and both sides of the 3-1/2-inch pieces.
- 5). Set the fence of the table saw at 3/16 inch over the blade. Raise the blade to 1/2 inch. Stand the 3-1/2-inch pieces on their ends and cut them on this setting. Do this for both ends and both sides of both pieces. This should result in producing a "tongue," which will fit into the groove on the 2-inch pieces. Fit the four pieces together to be certain of a good fit.
- 6). Cut a 1/8-inch piece of glass that measures 20 7/8 by 41 7/8. Apply glue to the tongue of one of the 20-inch pieces and set it in one of the 48-inch pieces. Next, place the glass in the grooves and apply glue to the remaining tongues and then slip the other 20-inch piece in place and finally set the last 48-inch piece where it goes. Clamp the door tightly with the two bar clamps. Clean up excess glue immediately with a damp cloth.
Source...