Flush-Mounted Doors

 

Steps 6 & 7

6 Sometimes, after all that careful work, you still might find yourself looking at imperfect reveals. If the gap is too large at one end, you'll have to chisel a thin layer of wood out of the nearest mortise, as shown above, left. When a reveal is too sli ght, loosen the screw in the carcase-side hinge and slip a piece of paper, sandpaper, or cardboard into the mortise to bump the hinge out just a bit, as shown above, right. Tighten the screw, and check the reveal again.

7 Another common problem: The reveal turns out fine, but the plane of the door doesn't line up with the face frame, as shown at left. Loosen the single screw placed in each carcase-side leaf, and place screws as shown in the inset. To shift the door out, put each screw against the outer edge of its hole. To pull the door in, put the screws against the inner edge. Once the door is lined up, remove the original screw entirely, fill the hole with toothpicks and glue, and drill a pilot hole after this plug hardens.

Finally, when everything is lined up just right, trim the knob stiles to produce a 1/16" reveal down the middle. Take the same amount off each door, using your tablesaw or a handplane, and bevel them slightly toward the inside. The bevel lets them swing open and shut without banging together at their inside edges.

Doors and Drawers Made Easy