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insulated sauna door and casing

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Project by patron posted 06-02-2012 12:25 AM 2366 views 3 times favorited 48 comments Add to Favorites Watch

my good friend daniel
ordered a door for his soon to be sauna room

as i do as much as i can to make his job easier
(he will install it)
i made a complete unit just like the ones from the store

except it needed to be insulated (according to me)
and with only 2×6 redwood to work with
i thought about this for a bit
and came up with a way to use some 1/4’ T&G western red cedar
i had from another job as cedar is the wood of choice for saunas

as the cedar was so thin it would not be able to span the door as paneling
without some internal help
so i made the door regular with mortice and tenons
and rabbeted a ledge around the inner frame to except the paneling on both sides
and put two 1”x 2” stiffeners top and bottom in the remaining 1” of space
and then re-sawed some 2” pink foundation foam to 1”
and inserted it into and between them

i put a lever handle on it
as i feel that opening it with sweaty hands
may be to much trouble for some people

the casing is also 2×6 redwood
(straightened and ripped to 5”)
with vinyl and foam door seals
and a threshold with a rubber seal also

my goal was to make the door as light as possible
and insulated and water repellent
so why the T&G paneling with the tongue up
it will be finished with BLO as that is the age old finish for this
(i don’t have any here so the pictures are a little bland yet
but i still have a week before he comes for it
by then it will be done

hope you enjoy
thank you for stopping in

i will now do a complete build tutorial of this build

edit: http://lumberjocks.com/patron/blog/30291

have a good weekend

-- david - only thru kindness can this world be whole . If we don't succeed we run the risk of failure. Dan Quayle





48 comments so far

View Joe Lyddon's profile

Joe Lyddon

7952 posts in 2807 days


#1 posted 06-02-2012 12:36 AM

WOW!

That looks like a pretty good-sized door!

Must be a good-sized sauna!

Sounds great!

It would be interesting to see how you did it… and what you used for insulation.

Looking forward to it…

-- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: http://www.WoodworkStuff.net ... My Small Gallery: http://www.ncwoodworker.net/pp/showgallery.php?ppuser=1389&cat=500"

View patron's profile

patron

13187 posts in 2096 days


#2 posted 06-02-2012 12:43 AM

thanks joe

casing is 79 1/4×32 outside
(that’s what daniel has room for)

will do a blog now
lot’s of new concepts and jigs for this build
many just standard too

-- david - only thru kindness can this world be whole . If we don't succeed we run the risk of failure. Dan Quayle

View amagineer's profile

amagineer

1392 posts in 1352 days


#3 posted 06-02-2012 01:00 AM

Nice looking door. I wonder if the heat from the sauna will bring out the cedar aroma.
_don

-- Flaws are only in the eye of the artisan!

View patron's profile

patron

13187 posts in 2096 days


#4 posted 06-02-2012 01:05 AM

that would be more like pencil aroma don
it is western red cedar
not aromatic cedar
and redwood is a cousin to WR cedar
so they are much alike

-- david - only thru kindness can this world be whole . If we don't succeed we run the risk of failure. Dan Quayle

View DIYaholic's profile

DIYaholic

14708 posts in 1430 days


#5 posted 06-02-2012 01:11 AM

Sweet door. That will look great finished with BLO and finally installed.

-- Randy-- I may not be good...but I am slow! If good things come to those who wait.... Why is procrastination a bad thing?

View grizzman's profile

grizzman

7193 posts in 2058 days


#6 posted 06-02-2012 01:22 AM

beautiful door david, ive seen many inside’s of saunas but you have made one that looks like the outdoors when you open it…amazing…lol…....i love projects like this, doing something a bit different then what we normally do, and you did this so fine..i love cedar and love the project, you have a lucky friend to get a david original

-- GRIZZMAN ...[''''']

View David Craig's profile

David Craig

2135 posts in 1864 days


#7 posted 06-02-2012 01:28 AM

Beautiful door David. I would love one for my own spa, except I would need the walls around it as well :) In the interim, I will look forward to your blog and be prepared when that day happens :)

-- There is little that is simple when it comes to making a simple box.

View patron's profile

patron

13187 posts in 2096 days


#8 posted 06-02-2012 01:28 AM

maybe the post needs to be offset grizz
so you can enter full bodied on one side
and come out thinner on the other

-- david - only thru kindness can this world be whole . If we don't succeed we run the risk of failure. Dan Quayle

View patron's profile

patron

13187 posts in 2096 days


#9 posted 06-02-2012 01:33 AM

thanks david
working on it now
may be a while still
lot’s of pictures

-- david - only thru kindness can this world be whole . If we don't succeed we run the risk of failure. Dan Quayle

View grizzman's profile

grizzman

7193 posts in 2058 days


#10 posted 06-02-2012 01:33 AM

oh i thought this was a two way door, with folks side stepping, , but the idea of coming out thinner is , well i . dont know if that will work for me, as i need to eat a dozen doughnuts before i go in to have the energy to last in there, and then another dozen when i come out to give me the energy to think about doing it again…so i might just get all heated up for nothing, but the doughnuts will be worth the thought…;)

-- GRIZZMAN ...[''''']

View patron's profile

patron

13187 posts in 2096 days


#11 posted 06-02-2012 01:37 AM

thick or thin
donuts are always in

-- david - only thru kindness can this world be whole . If we don't succeed we run the risk of failure. Dan Quayle

View Roger Clark aka Rex's profile

Roger Clark aka Rex

6940 posts in 2190 days


#12 posted 06-02-2012 02:03 AM

Good looking door David.
Love the first picture, looks like a door to NM country ….. you must be an artist too.

-- Roger-R, Republic of Texas. "Always look on the Bright Side of Life" - An eyeball to eyeball confrontation with a blind person is as complete waste of Time.

View BarbS's profile

BarbS

2434 posts in 2840 days


#13 posted 06-02-2012 02:06 AM

A very attractive door! And the insulation should work great. It’s no less than I’d expect of your work, David. Very fine.

-- http://barbsid.blogspot.com/

View patron's profile

patron

13187 posts in 2096 days


#14 posted 06-02-2012 02:08 AM

thanks roger

when i first walked thru it
i almost fell off the porch
so i moved it so i could clamp it to the post
for the pictures as the wind was howling

-- david - only thru kindness can this world be whole . If we don't succeed we run the risk of failure. Dan Quayle

View patron's profile

patron

13187 posts in 2096 days


#15 posted 06-02-2012 02:15 AM

hi barbs

it is surprisingly very light
and strong too

-- david - only thru kindness can this world be whole . If we don't succeed we run the risk of failure. Dan Quayle

showing 1 through 15 of 48 comments

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