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One year ago, I set out to make this Mission Style Mirror for my son and
daughter-in-law. It was a fun project that made use of the CMT Window Sash Set.
One regret I had was in using so many pocket-screws to hold all the
tiny pieces together. They worked fine, and they were hidden but still, a lot of
metal in a wood craft's project.
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This year, my sister moved to a new
house and wanted a mirror "...just like John's but a bit smaller."
I was determined not to use the pocket screws, but to mortise and
tenon the small pieces, if I could figure out how.
That is when a new set of bits were announced by CMT the CMT/Lonnie
Bird's Divided Light Door Set.
I just received a set and decided my sister's project would be a great way to
learn how to use this new set.
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For those of you who have the
traditional window sash kit, I will try to explain the difference.
The end result is much the same just a slight different profile. The
big difference is in these two bits: the profile cutter on the left is from the window
sash kit. The one on the right is from the new CMT/Lonnie Bird Divided Light Door Set. A
separate rabbeting cutter is part of the 3-bit set.
So what's the big deal about this? Well, it allows you to cut your
traditional mortise and tenon joints and then cope and profile to match.
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The new set comes with 4 pages of
instructions. They are pretty good, but not perfect, at least not to my level of
understanding.
But after a practice joint or two (or three, or...) I got it right, and I
think I can make repeatably good joints now.
So with that behind me, I will help Beth learn how to use this new set, and
together, we will make the mirror for my sister.
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As per the instructions, I
started by sanding the stock down to exactly 7/8" thickness. You can probably use
stock as thin as 3/4", but 7/8" is what the cutters were designed
for.
For information, the CMT Window Sash set was designed for real windows of
thicknessses from 1 1/4" to 1 3/8". The new set will be ideal for kitchen
cabinets and furniture that require glass/mirror doors and use the tradition 4/4 stock.
So, it is not one set replacing the other, but augmenting the other, depending on the
application. Much better to have this than to have to make one work for a thickness of
stock for which it wasn't intended.
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Next, I had to rip the board into final
dimensions. I decided the outside rail and stiles would be 1 1/2". I have set up the
Grip-Tite Fence System. I really like it for these kinds of ripping operations
actually, I like it for all ripping operations. [Go here for the
story on this system.]
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I switch blades to a brand new CMT
Cabinetmakers Blade. Frankly, the CMT General has been cutting so well, I didn't think
that a cabinetmaker's blade could do any better I was dead wrong. The finished cuts
were like glass with zero splintering. It will certainly make for great corners for this
project.
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I use my faithful Incra Miter Gauge to
cut all the rails and stiles to the exact length.
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I double check my measurements. I have
allowed for 1" mortises on the two stiles.
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