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Redwood Shop Doors

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Project by gizmodyne posted 2694 days ago 4710 views 22 times favorited 18 comments Add to Favorites Watch

Back Story
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.

The Build
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.

Little Touches

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.


Finish
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





18 comments so far

View frank's profile

frank

1492 posts in 2811 days


#1 posted 2694 days ago

Hi gizmodyne;
—-well these are some sharp looking doors, looks like you’ve done some nice work there!

I also went to your blog and then on to flickr, you’ve been busy from what I can see. I also noticed your workbench and then there’s the Jet bandsaw…..great tools you’ve got there.

Those hummingbirds are an added blessing!
GODSPEED,
Frank

-- --frank, NH, http://rusticwoodart.tumblr.com/

View Obi's profile

Obi

2213 posts in 2842 days


#2 posted 2694 days ago

Them’s nice doors.. they need a little weather stripping on the inside at the top.

View gizmodyne's profile

gizmodyne

1763 posts in 2695 days


#3 posted 2694 days ago

What’s weather? I live in California. :)

It’s on the to do list. Any suggestions?

-- -John "Do I have to keep typing a smiley? Just assume it's a joke." www.flickr.com/photos/gizmodyne

View oscorner's profile

oscorner

4564 posts in 2916 days


#4 posted 2694 days ago

So you went from a chair to garage door. Great work, gizmodyne!

-- Jesus is Lord!

View dennis mitchell's profile

dennis mitchell

3994 posts in 2920 days


#5 posted 2694 days ago

Yep great doors

View scottb's profile

scottb

3647 posts in 2932 days


#6 posted 2694 days ago

“pretty sweet for homespun”

I’d say pretty sweet for custom ordered!

beats the pants off the typical overhead model

-- I am always doing what I cannot do yet, in order to learn how to do it. - Van Gogh -- http://blanchardcreative.etsy.com -- http://snbcreative.wordpress.com/

View MsDebbieP's profile

MsDebbieP

18615 posts in 2766 days


#7 posted 2694 days ago

they are beautiful!!!
and what are the neighbours saying???

-- ~ Debbie, Canada (https://www.facebook.com/DebbiePribeleENJOConsultant)

View rentman's profile

rentman

230 posts in 2700 days


#8 posted 2694 days ago

nice!

-- Phil, Chattanooga,TN

View Don's profile

Don

2599 posts in 2782 days


#9 posted 2693 days ago

You do nice work Gizmo. Frank alerted me to your web site and I now realize you have some extensive woodworking experience. You are another great addition to this community!

-- CanuckDon "I just love small wooden boxes!" http://dpb-photography.me/

View Obi's profile

Obi

2213 posts in 2842 days


#10 posted 2693 days ago

I live in California too… weather i.e. that temperature below 60. I used to live in L.A. ... I can’t remember if it ever got below 60 when I was there. O.K. maybe you don’t need weather stripping.

View gizmodyne's profile

gizmodyne

1763 posts in 2695 days


#11 posted 2686 days ago

I am going to add some stop material. Mainly for sound protection. It’s on “the list”.

-- -John "Do I have to keep typing a smiley? Just assume it's a joke." www.flickr.com/photos/gizmodyne

View Fireball's profile

Fireball

65 posts in 2673 days


#12 posted 2659 days ago

Giz,

Beautiful doors! I’m a beginner so hopefully you’ll excuse all the questions.

Is western redwood the same as western red cedar that we have here on the east coast?

Also, you mentioned that you’ve seen some folks build a simpler version using a 2×4 frame and attaching the redwood to that. Can you explain what are the negatives of doing it this way?

Lastly, I’m not sure I understand how the beadboard layer was made. Is it a number of boards all joined together, or is it a number of bigger pieces with machine-made vertical lines?

Thanks for the help!

View gizmodyne's profile

gizmodyne

1763 posts in 2695 days


#13 posted 2658 days ago

Fireball.
The wood: My understanding is that they are different species with similar weather friendly characteristics that make them suitable to outdoor environements.
Here is an article comparing the two.

The negatives of doing the 2×4 method are… it’s not as aesthetically pleasing.

The advantages are it is cheap.. and quicker.

Probably these doors as constructed are an intermediate project but dont let that dissuade you.
You need access to a jointer or some way to straighten the long boards (table saw sled?).

Here is how I make Beadboard.
  1. Take individual boards and create some type of edge joint: Tongue and Groove or Shiplap. (these are shiplap). Now your boards will interlock on their edges.
  2. Run 1/2 a v-groove down the edges so that when they meet you will see a complete v-groove. ( On these doors I only did the front since the back is hidden.

Now if you want to create wider pieces of solid wood you can also space a true v-groove down the center of each board. This creates a faux beadboard look. This takes at least three separate router set-ups

Check out my blog on building beadboard doors .

Here is a picture of a stack of beadboard

If you are going to paint your project you can just run a series of equally spaced v-grooves on a piece of mdf.

Hope this is not too much info.

-- -John "Do I have to keep typing a smiley? Just assume it's a joke." www.flickr.com/photos/gizmodyne

View Sonny's profile

Sonny

309 posts in 2458 days


#14 posted 2166 days ago

those are nice dude….....

View Dan'um Style's profile

Dan'um Style

12855 posts in 2588 days


#15 posted 2166 days ago

bet you didn’t have your dominoe when you made this !

-- keeping myself entertained ... Humor and fun lubricate the brain

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