|Project by tommytenspeed||posted 02-07-2014 09:26 PM||1469 views||3 times favorited||5 comments|
Several years ago I decided I wanted to replace the interior doors in my home but they cost way too much and everything I had heard about making them discouraged me. I decided to throw caution to the wind and give it a try.
I settled on standard 6-panel design utilizing groove and stub tenon joinery. As I have always enjoyed laminating contrasting exotic hardwoods in a lot of my designs, I chose to use African Mahogany accents on Red Oak Doors.
I did not want to use solid 8/4 oak as I feared this would eventually twist, bow or warp so I face glued two 3/4” thick boards together to get the thickness I needed. I then jointed each blank to 3 1/2” wide and glued 1/4” thick pieces of African Mahogany to the sides. After face jointing one side and passing through the planer I sent each blank through the stationary drum sander to a final thickness of 1 3/8” (standard for interior doors). Each door requires approximately 3 blanks that are about 85” long (the panels are another story all together).
I then ran them through the table saw with a dado blade set at 1/2” to make the grooves that hold the panels and tenons. After glue-up a final sanding followed by staining and finishing produces a slab door. I made several jigs to mortise the hinges on the door and frame, cut the holes for the knob and latch and hung each one myself (ugh-they are heavy; about 95 pounds each for a 30” door).
It took me about a year and a half to make two 24” closet doors and four 30” bedroom doors.
The pictures above show the laminate fairly well and the other 3 are samples I made just to see what a Walnut door trimmed in Hickory, Cherry door trimmed in sapele and a Red Oak door trimmed with Padauk would look like.
Making doors is not nearly as hard as everyone made it out to be. I enjoyed making these and will probably make some for friends and family.