2" Solid Mahogany Door

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Project by David posted 08-01-2011 03:35 PM 1725 views 0 times favorited 3 comments Add to Favorites Watch

I’m adding a new deck to the back of my building and had an access hole knocked in the wall to put a door. As I was limited to the size of the door frame due to the fact that its in what used to be a pantry, I had to build a custom door (28” X 80”). I chose mahogany as its supposed to hold up well to the elements. Used 8/4 with M&T joints. Glue-up was a near disaster as I almost couldn’t get the joints to go together as the cuts were a bit too tight. But with the butt of an axe and shear brute force they came togeher nicely. I built a panel for the middle which I mitred down with a router and a custom built jig. Glass is double pane 1” thick tempered and storm resistant. I put the weight at at least 200lbs. Hanging it was a nightmare. I used three 4” hinges and a lot of patience. All-in-all it took me about 4 hours to hang. I finished with several coats of tung oil/poly mixture. I imagine I’ll have to re-coat at least once a year to keep out the elements. Hope it holds up…..


-- dcutter

3 comments so far

View jbschutz's profile


539 posts in 2713 days

#1 posted 08-01-2011 03:43 PM

David, Great looking door! Mahogany is a great outdoor wood, but you are right in planning on frequent refinishing. Sun is the greatest enemy. If your door has a southern exposure, you will be waging a constant battle to keep the finish in good shape. One thing you might want to explore is the newer “spar” poly varnishes. There are some pretty good ones available, that will stand up to the elements and not require yearly renewal.

-- jbschutz

View MasterSergeant's profile


1364 posts in 2710 days

#2 posted 08-01-2011 06:15 PM

You gave me inspiration. We just finished building our home but still need storm doors, I’m going to have a go at building them just as soon as the weather turns a little cooler (my shop has no AC :( \
Thanks for showing this to us.

-- Kelly, woodworker under construction

View Bertha's profile


13529 posts in 2715 days

#3 posted 08-01-2011 06:58 PM

Wow, you really went all out on this one. It’s beautiful. I always thought mahogany held up pretty well to the elements. Am I mistaken? I hope not because I made a friend a canoe yoke out of it!

-- My dad and I built a 65 chev pick up.I killed trannys in that thing for some reason-Hog

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