Entry Door Between Garage and House

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Project by Rich posted 02-19-2017 06:30 PM 2088 views 6 times favorited 14 comments Add to Favorites Watch

This is an entry door that I built and hung in the entrance from the garage to the house. It is made entirely from 8/4 S2S clear alder, stained by my wife, and then I sprayed it with multiple coats of satin Deft brushing lacquer thinned to 50% with lacquer thinner and acetone. The door is 36” wide by 80” tall, 1-3/4” thick with 1-1/2” thick panels. The groove for the panels is 5/8”, which means the tenons are 5/8” as well (as opposed to 3/8” for my interior doors). The tenons are 2” long for strength, and I used plastic resin glue for all of the glue ups.

The overall weight of the door, with hardware, came to 80 lbs.

Since local code requires fire retardant, I went with the Flame Stop II product which is used in many commercial environments as well as resorts and amusement parks like Disney World.

Using the flame retardant made staining particularly difficult, since it penetrates deeply and resists the acceptance of the stain. It also was a pain, since it requires a water based stain, which my wife hates. She went through about two dozen sample boards that I resawed from the alder stock and prepped to match the surface of the door before she was satisfied with the result.

Syringes with 12 ga blunt tips are excellent for getting the glue into the mortises, and also allow metering of glue quantities.

-- No matter how much you push the envelope, it'll still be stationery.

14 comments so far

View Kelster58's profile


523 posts in 474 days

#1 posted 02-19-2017 08:29 PM

That is really nice. You did a GREAT job. Fit and finish is second to none.

-- K. Stone “Tell me and I forget, teach me and I may remember, involve me and I learn.” ― Benjamin Franklin

View JoeinGa's profile


7733 posts in 1940 days

#2 posted 02-19-2017 08:56 PM

Dang son! THAT is a very nice door !

-- Perform A Random Act Of Kindness Today ... Pay It Forward

View helluvawreck's profile


30512 posts in 2800 days

#3 posted 02-20-2017 02:59 PM

You did a beautiful job on this entry door.

helluvawreck aka Charles

-- helluvawreck aka Charles,

View trialrun's profile


41 posts in 741 days

#4 posted 02-20-2017 05:11 PM

wow, came out great!

View Bobsboxes's profile


1345 posts in 2597 days

#5 posted 02-20-2017 05:31 PM

Very nice door, great finish.

-- Bob in Montana. Kindness is the Language the blind can see and deaf can hear. - Mark Twain

View EarlS's profile


812 posts in 2282 days

#6 posted 02-20-2017 06:12 PM

Gorgeous looking door. I hadn’t heard of Flame Stop before. Looks like your wife did a great job on the stain afterwards.

-- Earl "I'm a pessamist - generally that increases the chance that things will turn out better than expected"

View Mean_Dean's profile


6340 posts in 3081 days

#7 posted 02-20-2017 11:47 PM

That’s a great looking entry door—I like the door (and the hardware is the same as I have in my house!)

And yea, I know fire codes are a pain. Around here, these doors are required to be 20-minute fire doors, but if the staining process takes a bit longer, it’s worth it.

-- Dean -- "Don't give up the ship -- fight her 'till she sinks!" Capt James Lawrence USN

View sras's profile


4767 posts in 3063 days

#8 posted 02-22-2017 04:47 PM

Beautiful! Good tip on the flame retardant.

-- Steve - Impatience is Expensive

View Rich's profile


2474 posts in 523 days

#9 posted 02-22-2017 06:09 PM

I appreciate the nice comments. I was sure to let my wife know too. She was cussing the whole time she was doing the staining.

Regarding the flame retardant, we spoke with a fire inspector at the local firehouse and he said that if a fire broke out in the garage, it would come in through the wall, not the door — flame retardant or not. We just wanted to be sure to be code-compliant so the insurance company wouldn’t have that to gripe about. Hopefully, there won’t be any reason to test it :)

-- No matter how much you push the envelope, it'll still be stationery.

View Woodknack's profile


11311 posts in 2314 days

#10 posted 03-25-2017 01:38 AM

The fit and finish on this are pro, and I’m guessing you are a pro. :)

-- Rick M,

View oldrivers's profile


1254 posts in 1500 days

#11 posted 04-29-2017 11:31 AM

That is one Beautiful, well constructed door, can’t buy one like that on the market.

-- Soli Deo gloria!

View Rustyempire's profile


24 posts in 547 days

#12 posted 07-28-2017 07:21 PM

Really beautiful Rich!

View TheSawDustWhisperer's profile


30 posts in 55 days

#13 posted 02-07-2018 11:23 PM

Marvelous door! I also like all of your other projects. I haven’t made any large doors and would like to make new doors to replace all my cheep hollow core interior doors. If I can ask. On the door rails, why didn’t you make a full tenon instead of making 2 smaller ones.
Thanks. Was there much sawdust created during the making of this project?

-- Dusty Lungs

View Rich's profile


2474 posts in 523 days

#14 posted 02-08-2018 01:27 AM

On the door rails, why didn t you make a full tenon instead of making 2 smaller ones.
Thanks. Was there much sawdust created during the making of this project?

- TheSawDustWhisperer

Generally, on tenons wider than about 3 or 4 inches, you need to start thinking about wood movement. The tenon is cut cross grain, and the mortise is along the grain, so if the tenon is glued along it’s full width, there is a risk of cracking as the rail changes in width. To deal with that, you can cut a full tenon and only glue it at one point, but I prefer to cut two tenons and only glue one, leaving the other to float.

Regarding sawdust, there’s a lot less for entry doors, since it’s 1-3/4” thick and less is planed off for the rails and stiles. It’s the interior doors, where 8/4 boards get planed down to 1-3/8”, that fill up Hefty bags pretty quickly. We sold our horses a while back, but still have friends in the equine world who love the shavings though, so it’s not wasted.

-- No matter how much you push the envelope, it'll still be stationery.

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