This is the way.

Ya. I think the math worked out to about an 18" disk.

I jointed the stick straight, planed it for thickness and width, used a shaper to chamfer and the side dados. Sled jig with stop to cut to length, then sled jig with shaper for end dados. I built a carousel jig for the bandsaw for the rough radius, then used a belt sander with a right angle table to smooth them out.

Thank you! Figuring out the process the first time around was…challenging. My first brilliant idea was to use a carousel jig with a big straight knife head on the shaper. All it made for me was splinters as every piece I ran through grenaded on me. After I cleaned out my pants, it was back to the drawing board.

Thank you! I do. I’ll work on getting some other pics of the piece up.

Primarily longevity. This is for an exterior entry door. Also, I find veneer work tedious. I stick with solids whenever possible.

Thank you. Will do.

Thanks! I jointed the stick straight, planed it for thickness and width, used a shaper to chamfer and the side dados. Sled jig with stop to cut to length, then sled jig with shaper for end dados. I built a carousel jig for tha bandsaw for the rough radius, then used a belt sander with a right angle table to smooth them out. I make extensive use of micrometers and digital readouts in my shop; very accurate sizing is the key to getting something like this together without gaps.

Kurt Vonnegut: “America is the wealthiest nation on Earth, but its people are mainly poor, and poor Americans are urged to hate themselves.” The converse is also true in that Americans are trained to worship the rich, and to think they deserve all the help they can get, up to, and including, socialism for the wealthy, and rugged capitalism for the rest of us. This is reflected in corporate philosophy.