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Old 07-08-2012, 11:07 AM   #16
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what are you up too?


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Old 07-08-2012, 11:12 AM   #17
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Originally Posted by Tom Struble View Post
what are you up too?
My dog can smell a cookie on top of a door
"I'm not as green as I am cabbage looking"
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Old 07-10-2012, 02:51 PM   #18
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For a solid door (probably work with foam core):
You will need
  • Rockler Self Centering Doweling Jig
  • 1/2" x 18"OAL HSS Extra Long Drill Bit, Straight Shank
  • 1" to 3" Timber Framers' Slick ( A slick is a mortising chisel with a real long handle, maybe 24")
  • Small piece of 2 x 6 and plywood to build jig
  • A lot of patients
  1. Use the 2 x 6 and plywood to build a jig to hold the bit straight. The regular dowling jig is not sturdy enoug to hold straight for a 12 in depth. The plywood sides should go down at least 18 inches to be self supporting.
  2. Use the 1/2" bit to create the hole in the jig. Probably want to create more than one, because you will eventually enlarge the hole after a few passes.
  3. Slowly drill a series of holes across the top
  4. Use the slick to straighten the sides. Leave the end rounded. Slowly taking 1/8 slivers.
For hollow core doors:
  • Mibro 366291 Ultimate Door Lock and Hinge Installation Kit for Wood Doors
  • 1/2" Mortise Chisel
  • 1/2" thick x 1" wood
  • 1/8 hardwood plywood, hardboard or polycarbonate sheets
  1. Use the small hole saw and jig from Mibro kit to drill series of holes in the top of the door. It should make it to the hollow core
  2. Use the mortise chisel to square up the box. Also mortise out 1/2 deep about 2 inches each side of the opening.
  3. Build a box out of the wood and or polycarbonate. The top of the box extends 2 inches past each side. The back should be solid and the top 1/4 of the front should be open for access.
I make no guarantee about the integrity of the door. Congratulations you have now spent about $300 to gain 50 cubic inches of storage.


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