This resulrs in "horns" that will be trimmed off later (Fig. A).
Cut the mortise and tenon joints for the frame. I chop the mortises in the stiles using a hollow-chisel mortiser, and saw the tenons on my tablcsaw. When cutting the tenons on the top and bottom rails, cut only the face-side shoulders (see Photo 1).
Draw the curve on the top rail, saw to shape (Photo 1) and sand the shape smooth (Photo 2). On traditional frame-and-panel doors like these, I prefer a molded inside edge on the frame, callcd "sticking." Rout the molded edge on your top rail, bottom rail and stiles, using a 3/32-in. roundover bit in your router table (Photo 3). Use a starter pin in your router table for the curved top rail, and a straight fence for the other parts. Then groove the frame members to receive the panel (Photo 4), using a piloted slot cutter. Miter the molded edge on both rails and stiles (Photo 5), and cut the back-side shoulders on the tenons. Use a tablcsaw to cut the unwanted molded edge from the ends of the stiles. (For more details on making this kind of molded frame, see "Mitered Sticking," #50, Feb. 1996.)
BANDSAW THE CURVE in the top rail, after cutting the tenons. Saw on the waste side of your layout line. Only one shoulder of the tenon is cut at this stage.
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There are a lot of things that either needs to be repaired, or put together when youre a homeowner. If youre a new homeowner, and have just gotten out of apartment style living, you might want to take this list with you to the hardware store. From remolding jobs to putting together furniture you can use these 5 power tools to get your stuff together. Dont forget too that youll need a few extra tools for other jobs around the house.