| Project by DaytonB | posted 97 days ago | 836 views | 10 times favorited | 17 comments |  |
 |
African mahogany entry door.
This was a great learning experience. I learned you can’t just build an all wood door, you mush first “build” the lumber used to construct it, nearly half of the time required to build a solid wood door, that wont warp, is spent preparing the wood. Once done with this step the average person would not be able to tell that you had done anything towards building the door.
When building the panels you must have separate interior and exterior panels so that the outside and inside environments aren’t both working on the same piece of wood. I resawed a 6/4” board in half, then planed them down to about 1/2”, I then glued the inside and out side panels to a 1/2 MDF core in a vacuum bag, (this was a tip given to me by master craftsman and fellow LJ Les Hastings) the MDF functions as a stable core and insulation for the panels.
I used a stave core design, the idea here is to glue strips or staves together with alternating grain patters so that when one stave wants to move a sertain way there are several others fighting it, keeping the over all rail or stile from warping. First off you cut the 8/4 stock down into approx 1 1/2” square staves. Then mix them up and flip some end-for-end then gluing them back together. Once dry, jointed and planed, you glue a 1/4×5 1/2” veneer, that is cut from another solid board, to both sides of each stave block , this is so that once glued the board will look like solid lumber again. The 6th picture above is end cuts of a stile and panel, you can see the staves and outer veneers, the black is end grain paint.
2” mortise and tennons along with 1/2×3” dowels (2 per side for top and middle rail and 4 on the bottom) were used to construct the door, there is also 4 bolted steel thread rods (2 in bottom rail and one rod in each of the other two rails) running the width of the door. These were covered with custom cut plugs.
I used a marine epoxy (recommended by Les Hastings) for most of the construction, but ran out so I finished with some titebond 3. The finish is 3 coats of a wiping varnish using 1/3 spar polly, 1/3 tung oil, 1/3 B. linseed oil. Then 3 or 4 more coats of straight spar varnish.
Leaded light
This was my first leaded glass project but I have a good friend who is a retired leaded light maker. He loaned me the tools needed and gave me several pointers and a couple books. I’m very pleased with how it turned out.
The door has been hanging for approx 5 months now, through very high temps and humidity outside and cool, low humidly inside, with no noticeable movement.
dayton
www.daytonwooddesign.com
17 comments so far
degoose
home | projects | blog
1981 posts in 247 days
posted 97 days ago
You certainly did a wonderful job on the door and thanks for all the insider info on construction,
Larry
-- Drink once, cut twice. New website up.... lazylarrywoodworks.com.au
Innovator
home | projects | blog
3125 posts in 306 days
posted 97 days ago
That is one beautiful door, great job.
-- Whether You Think You Can or You Think You Can't, YOU ARE RIGHT!!!
John Daugherty
home | projects | blog
6 posts in 329 days
posted 97 days ago
That is one great looking door. I also really like the glass. That african mahogany is some great looking stuff.
socalwood
home | projects | blog
968 posts in 497 days
posted 97 days ago
At the top of your bottom rail how do you prevent water from soaking into your panel bottoms ?
-- rob
Les Hastings
home | projects | blog
953 posts in 666 days
posted 97 days ago
Looks like its holding up great Dayton. Great choice on the glass, awesome looking door!
-- Les, Wichita, Ks. (I'd rather be covered in saw dust!)
kolwdwrkr
home | projects | blog
2248 posts in 483 days
posted 97 days ago
beautiful door
-- ~ Inspiring those who inspire me ~
Beginningwoodworker
home | projects | blog
4123 posts in 566 days
posted 97 days ago
Nice front door.
-- CJIII Future cabinetmaker
huff
home | projects | blog
1608 posts in 178 days
posted 97 days ago
Awesome door! The glass is a perfect touch. Thanks for sharing all the info. Never knew there was so much to making a door.
-- John @ Myrtle Beach
GarageWoodworks
home | projects | blog
204 posts in 516 days
posted 97 days ago
Nicely done. This is a project that I’ve wanted to try for some time, but I’m a little nervous about.
Great build!
-- Brian http://www.garagewoodworks.com
Splinterman
home | projects | blog
4827 posts in 254 days
posted 96 days ago
Good design and finish…..well done.
-- I will just keep doing it till I get it right.
dhg
home | projects | blog
148 posts in 605 days
posted 96 days ago
It’s beautiful! nice job.
-- Talent on Loan from God - Rush Limbaugh ----------www.genesiswoodworks.com----------
Rick
home | projects | blog
63 posts in 103 days
posted 96 days ago
That sounds difficult. Looks amazing though. I think I’ll hire you if my wife ever asks for one.
DaytonB
home | projects | blog
119 posts in 759 days
posted 96 days ago
Thanks for all the complements guys, I appreciate it.
Rob (socalwood) this door is under a N-NE facing porch so it is not exposed to much water or any direct sun, it is possible for some water/moisture to get between the bottom rail and the panel but that area was pre-finished with 2 coats of varnish, I also put a bead of 100% silicon calk in the channel before inserting the pre-finished panels during assembly. The 7 or 8 coats of finish applied after assemble should also help limit any water intrusion.
Thanks
dayton
bfd
home | projects | blog
418 posts in 700 days
posted 96 days ago
Stunning! Thanks for the detailed info on the build and including the section shot. The craftmanship and design are stellar.
-- Brian, Folsom, CA http://www.brianfullerdesigns.com
woodtag777
home | projects | blog
19 posts in 234 days
posted 96 days ago
Wow!!! love the door, have attempted to build 3 so far, and none as beautiful as yours. I have been using 2×4’s and pallets to practice with. I wish i could use “real” wood. Excelent job, I would not have thought to use veneers, or one to stand up to the weather.
a1Jim
home | projects | blog
16684 posts in 470 days
posted 96 days ago
fantastic door looks great
-- Jim from Heirloom Woodshop Southern Oregon
mmh
home | projects | blog
1382 posts in 615 days
posted 88 days ago
VERY impressive door! Especially for a first time effort. I’ve been wanting to build a custom door, but I think I may need some help with the techniques. Let me know when you’re in Maryland and ready to make a custom door!
-- "They who dream by day are cognizant of many things which escape those who dream only by night." ~ Edgar Allan Poe