Aside from replacing the wood on the antique doors, this leaded glass cabinet doors project will involve building the body of the cabinet. Firstly is working backwards i.e., working around the size of our antique doors. Measure the existing cabinet door size. Add space for rails at the top, bottom and sides to give the overall dimensions of the cabinet. Determine the rail size and add the lower and upper cabinet frame for the total cabinet height based on the plans. Rip the boards for the sides, top, bottom, and shelves to the length and depth you will need. Biscuit joints can be used to join two boards together and achieve the necessary width in cases where the boards aren’t wide enough to achieve the proper depth.
Begin to build the leaded glass cabinet doors by using a biscuit joiner, cut biscuit-slots in the center of the board’s edges where biscuits can be added to connect the boards. Cut biscuit slots 8 inches on-center. Run a bead of glue along the edge of the board and inside the biscuit joint, then place the biscuits inside and connect both pieces of wood. With the boards joined together, clamp the wood, flip and add more clamps to the other side.
Allow four hours for the glue to dry when installing leaded glass cabinet doors. Remove the clamps and scrape off any glue that squeezed through the boards with a carbide scraper. Rip down the board to fit in the thickness planer (Image 3) and plane each side of the boards to a thickness of 3/4″. Rip each board down again to the actual cabinet depth. Cut dados in the sides and bottom panel to support the shelves and backing. For the backing use boxcar siding which fits together in a tongue-and-groove configuration. Cut each piece of boxcar siding to length. Sand down any rough edges on the wood.
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