What is the best way to make divided lite doors with diamond lites I have a 3 horse porter cable 1/2 shank in a router table i would rather have a two piece set than a combo set thank you.
- Wallis
Mission Viejo, CA
Divided Lite Doors with Diamond Lites
Our Expert
Divided light doors with diamond shapes are very challenging. I've provided an example in the drawing which uses a two-piece mullion. The main part of the mullion is a 1/8" thick strip of wood which is mortised into the stiles and rails of the doors. Where the mullions intersect at ninety degrees a half-lap joint is used. The rest use miters and epoxy.
After assembling the door the second part of the mullion is applied. This is a decorative cap which fits over the 1/8" sticks. A 1/8" wide groove under the cap strengthens the assembly and aligns the cap as it is applied. The completed door is surprisingly strong once it is fully assembled.
Glazing putty is used to hold each pane of glass in place. The putty should be tinted to match the color of the wood.