|Project by David||posted 08-01-2011 03:35 PM||1262 views||0 times favorited||3 comments|
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…..