Glass panels in dado

[curlyoak]

I tried to talk them out of it, to no avail. I'm building an outdoor cypress door. They want the glass inserted into the dado. Just like a wooden panel. 

Do I make the dado with a slight friction fit? Or something else.

Do I  use these little rubber balls/spacers?

How deep for the dados? and how much extra in the dado.

I really wanted a rabbit with mitered molding. But not my decision.

Thanks for your thoughts!

[Chet]

I would hope that you can get them to re-think this and go for the rabbet and mitered molding.  If you do the dado like a wood panel, how would they replace the glass if it were to ever get broken?

On 3/28/2024 at 10:57 AM, curlyoak said:

Do I  use these little rubber balls/spacers?

I use this, Lexel Silicone instead of space balls.  Just a few dabs along the rabbet... or dado if they don't change their mind.  It drys super clear.

[curlyoak]

On 3/28/2024 at 2:37 PM, Chet said:

would hope that you can get them to re-think this and go for the rabbet and mitered molding.  If you do the dado like a wood panel, how would they replace the glass if it were to ever get broken?

I hear you. I have tried every which way and they won't give in.

[Botch]

Is this an outside door to a house, or something else?  

I've built doors with glass panels, just made the dados extra-deep and nailed thin wooden strips into the side of the dado on top of the glass, so if it's broken the strips could be pried away to replace the glass if required (maybe that's what you're meaning by "mitered molding").  I may be completely misunderstanding this.  

[wtnhighlander]

I would be concerned that a groove loose enough to avoid glass breakage from wood movement would leak like a sieve.

And using such a groove also means you'll have to pre-finish before assembly, or have to clean a lot of finish off the glass. I suggest you remind your client that the reasons WHY glass panels should be fit with rabbets and trim were discovered long, long ago, and the physics hasn't changed.

[curlyoak]

If water gets in the dado the door still has fighting chance because it is cypress. But still would like to do it with a rabbet and silicone.

[Coop]

Almost a project you may want to back away from as you can almost bet it’s gonna come back and bite you in the butt. I agree with all of the above for all of the same reasons, except for your customer! 

[Mark J]

+1

[curlyoak]

I broke the code. I spoke to an aware architect to add to the list of objectors about the issue. With that the rabbet has been rescued! All is well.

[Mark J]

Hurray! 

[curlyoak]

Next step is to route the rabbets.

Above is the jumbo version used for doors and other large projects. My third door using it. A huge savings of time compared to mortice and tenon.

[curlyoak]

The varnish...

Retaped after each coat...