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Entry Door Between Garage and House

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Project by RichTaylor posted 02-19-2017 06:30 PM 1290 views 4 times favorited 10 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.

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10 comments so far

View Kelster58's profile

Kelster58

275 posts in 145 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

JoeinGa

7663 posts in 1611 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

helluvawreck

25316 posts in 2471 days


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

You did a beautiful job on this entry door.

helluvawreck aka Charles
http://woodworkingexpo.wordpress.com

-- If a man does not keep pace with his companions, perhaps it is because he hears a different drummer. Let him step to the music which he hears, however measured or far away. Henry David Thoreau

View trialrun's profile

trialrun

21 posts in 412 days


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

wow, came out great!

View Bobsboxes's profile

Bobsboxes

1258 posts in 2268 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

EarlS

397 posts in 1953 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

Mean_Dean

5389 posts in 2752 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

sras

4474 posts in 2734 days


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

Beautiful! Good tip on the flame retardant.

-- Steve - Impatience is Expensive

View RichTaylor's profile

RichTaylor

540 posts in 194 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 :)

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View Rick M's profile

Rick M

8957 posts in 1985 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. :)

-- http://thewoodknack.blogspot.com/

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