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