I started in on the pocket doors today. Each door needs to come down and have four things done to it before it is rehung. These are not the original pocket doors. Except for the track and a partial piece of hardware to hang a door, the original doors where long gone by the time I got here.
These are period salvage doors I purchased locally. They are redwood, but they were not originally meant to be pocket doors. They were a large pair of French Doors, most likely from some public building. This causes some problems. First they are too thin to have traditional pocket door hardware. Second, they are a little too wide for the space. Third, they were a little too short for the space.
The router bit is a half inch wide and the bushing is three quarters of an inch. That means that when the bushing rides against the inside edge of the jig, the resulting hole will be narrower in width than the hole on the jig by exactly a quarter inch.
The widest part of the key hole shape on the pull is inch and three quarters and the width of the narrow part is inch and an eighth. I used a two inch hole saw and an inch and three eights hole saw to make the jig, so the jig would be exactly a quarter inch wider than the key hole shape on the pull. The really odd thing here is that I own exactly three hole saws. One was two inch and another was inch and three eights. What are the odds?
What all of that means is that when I run the router on the inside of the jig it makes a hole that is exactly the size of the key hole shape on the pull because the pushing accounts for the extra quarter inch. It is a thing of beauty.
I hope to finish up the doors tomorrow and get them rehung. After that I can start to think about picture rail. Of course, I still need to decide on a paint color.