My daughter and son-in-law are needing a bigger gate to contain their Australian shepard from getting into the main room. The short-term fix was to cut a hollow-core door in half, fill in part of the hollowed space with wood, and place a small shelf on top. It was painted to match the other doors, but the looks were meh.
I got four 4/4x6x8' poplar from local big box, cut a pair to 44", another pair to 30". These were glued together to form 1.5" blanks.
After the glue dried, I ran through the planer to reduce thickness to 1 3/8".
I put in a 1/2" dado stack and cut a dado 7/8" deep down the middle of each of the blanks. These will be holding the 1/2" plywood panels. I separated the stiles so the outside measurement would be 32", then measured the inside distance, then added 1.5" to the overall measurement (to allow for the tongue on the rails, 3/4" on each end).
Another 4 boards were cut and glued to make the interior rail and stiles, milled to same thickness, and dados cut as before. Dry fit together, then measure the panel openings, and add .5" to each end to fit in all the dados.
Sanding is next, followed by primer and paint.
I got four 4/4x6x8' poplar from local big box, cut a pair to 44", another pair to 30". These were glued together to form 1.5" blanks.
After the glue dried, I ran through the planer to reduce thickness to 1 3/8".
I put in a 1/2" dado stack and cut a dado 7/8" deep down the middle of each of the blanks. These will be holding the 1/2" plywood panels. I separated the stiles so the outside measurement would be 32", then measured the inside distance, then added 1.5" to the overall measurement (to allow for the tongue on the rails, 3/4" on each end).
Another 4 boards were cut and glued to make the interior rail and stiles, milled to same thickness, and dados cut as before. Dry fit together, then measure the panel openings, and add .5" to each end to fit in all the dados.
Sanding is next, followed by primer and paint.
