|Project by gizmodyne||posted 03-17-2007 03:33 AM||6752 views||25 times favorited||18 comments|
I knew I would not be satisfied with a store bought garage door, so I took many walks around the neighborhood checking out old garage doors. I drew up a plan for these, and bought a huge load of clear redwood. The 8” jointer was acquired during the course of this project. I made these under time pressure, since we were going on a trip and I needed to secure the shop.
I learned the sandwich construction method from a “fine homebuilding” article. Each door consists of four layers. The front and back stiles and rails are 1” wider then the middle layers to create a rabbet when the parts are glued up. Rails and stiles are pocketscrewed and glued. Each layer was glued (Titebond II) and brad-nailed/clamped together. (I had to remember not to put brads where the rabbet goes.
I made the front firstm and perfectly square; then erred oversized for the remaining layers. Any overlap was corrected with a flush trim bit and my router.
The visible bead board filler was created by constructing shiplap joints and then running each slat across a v-bit in the router table. I actually used my jointer’s rabbeting feature for the shiplap.
The final layer of door is plywood which makes these suckers heavy and diffucult to hang.
I laid out the sapwood to create a pattern across both doors. Also the grain of the rails runs across both doors. The inner stiles of the left door is actually 1/2” larger to accomodate for the rabbet where the doors meet.
Thompson’s Water Seal. (Let’s see how that goes, but my gardener kept hosing the driveway near the doors!!!! GRRR!)
I think they are pretty sweet for homespun.
Picture 1: Both doors installed and finished.
Picture 2: Visible pocket screws and the craggy joint I cut to accomodate the second layer’s longer rails.
Picture 3: The doors from the inside.
-- -John "Do I have to keep typing a smiley? Just assume it's a joke." www.flickr.com/photos/gizmodyne