We’re slowly changing the decor of our summer home to G&G. The newest project is a door to our bedroom. We have a door there now but it’s an exterior door with glass which doesn’t provide much privacy.
I bought some mahogany door rail and stile material at an auction. It’s made of 5/16” skins on a plywood core. I also bought some rough 4/4 mahogany which I’m not that happy with but I only need it for molding and possibly the door frame.
I cut the pcs to rough length, made the mortise and tenons and cut in the hinges.
I didn’t have my long clamps with me to glue up the center section of the door. I used a board and screwed some scrap pcs to the end of it. Then made two oak wedges to apply clamping pressure.
Glued the stiles up. So far everything is fitting up nicely.
Starting on the quarter round molding. I need to make the molding go around the curves too.
The door is ready to be finished. I’m using a wash coat of shellac, Mohawk grain filler, mahogany gel stain and deft oil finish.
Door is ready for the stained glass now.
Someone asked for details on making the stained glass. This project was my first attempt. It took a while to learn how to cut the glass properly. It isn’t perfect but its good enough for a cabin.
There are two methods used to make stained glass panels. The one I chose is the traditional Leaded glass where glass is cut into the desired shape and lead Came is wrapped around the glass then soldered together. Came comes in several shapes and sizes. i used 1/4” round which is basically shaped like a dowel rod with a dado on each side to accept the glass.
The other method is Copper Foil method where copper foil is wrapped around the glass edges then soldered together around the entire edge. I’m not an expert in these methods but I believe the following is true:
Stronger and has a more uniform edge around the glass.
There are more steps to complete it
The glass needs to fit together better with copper foil to have strong, uniform solder lines
I learned how to do leaded glass on youtube and i got tips from the people at the stained glass shop. The high level steps to doing leaded glass are:
Select pattern and glass
Make a board with a raised wood corner to hold the glass in place as you’re assembling the project.
Transfer the pattern to the glass
Cut and grind the glass to fit the pattern
Fit the pcs together with lead came. Scrap wood and nails are used to push the material into the corner of the board.
Clean all the marks off.
Solder the joints
Fill the came with black stuff that is like plumbers putty. It hardens, seals and provides some strength.
Use a stiff brush to remove the excess putty
Clean the came with steel wool
Apply patina to the came
Polish with a brush
I didn’t take any intermediate pics. There is a learning curve to cutting the glass. I bought about 50 pct extra but I can use it on other projects.
Generically speaking it costs $125 – 200 per sqft to have custom stained glass made where I live. I bought some new equip and some used stuff. There are 9 sqft in this project. I have roughly $450 in material/equipment and have plenty of raw material for other projects.
-- Sorry the reply is so long. I didn't have time to write a short reply.