LumberJocks Woodworking Forum banner
5K views 36 replies 22 participants last post by  toddc 
#1 ·
Demystifying Door Construction

Constructing doors can seem intimidating. In this video I share with you how I built a custom door and demystify the process of door construction.

Watch Demystifying Door Construction

Fixture Wood Stairs Wood stain Floor


One of the ideas that I really want to impress on everybody is this: Don't be intimidated by new projects. When approaching a new project, most of the woodworking actions needed for it, you have done on other projects. By recognizing this, you create the mindset you need to build something that seems intimidating such as a door.

I hope you enjoy and find the video helpful.

Your friend in the shop-

Todd A. Clippinger

Share the Love - Share the Knowledge
 

Attachments

See less See more
2
#2 ·
Demystifying Door Construction

Constructing doors can seem intimidating. In this video I share with you how I built a custom door and demystify the process of door construction.

Watch Demystifying Door Construction

Fixture Wood Stairs Wood stain Floor


One of the ideas that I really want to impress on everybody is this: Don't be intimidated by new projects. When approaching a new project, most of the woodworking actions needed for it, you have done on other projects. By recognizing this, you create the mindset you need to build something that seems intimidating such as a door.

I hope you enjoy and find the video helpful.

Your friend in the shop-

Todd A. Clippinger

Share the Love - Share the Knowledge
Hi Todd, it's good to see your staying busy…..
 

Attachments

#3 ·
Demystifying Door Construction

Constructing doors can seem intimidating. In this video I share with you how I built a custom door and demystify the process of door construction.

Watch Demystifying Door Construction

Fixture Wood Stairs Wood stain Floor


One of the ideas that I really want to impress on everybody is this: Don't be intimidated by new projects. When approaching a new project, most of the woodworking actions needed for it, you have done on other projects. By recognizing this, you create the mindset you need to build something that seems intimidating such as a door.

I hope you enjoy and find the video helpful.

Your friend in the shop-

Todd A. Clippinger

Share the Love - Share the Knowledge
Thanks Bob, this has been the best year for me since the recession hit.
 

Attachments

#4 ·
Demystifying Door Construction

Constructing doors can seem intimidating. In this video I share with you how I built a custom door and demystify the process of door construction.

Watch Demystifying Door Construction

Fixture Wood Stairs Wood stain Floor


One of the ideas that I really want to impress on everybody is this: Don't be intimidated by new projects. When approaching a new project, most of the woodworking actions needed for it, you have done on other projects. By recognizing this, you create the mindset you need to build something that seems intimidating such as a door.

I hope you enjoy and find the video helpful.

Your friend in the shop-

Todd A. Clippinger

Share the Love - Share the Knowledge
Todd,

Good to see you posting again.
 

Attachments

#5 ·
Demystifying Door Construction

Constructing doors can seem intimidating. In this video I share with you how I built a custom door and demystify the process of door construction.

Watch Demystifying Door Construction

Fixture Wood Stairs Wood stain Floor


One of the ideas that I really want to impress on everybody is this: Don't be intimidated by new projects. When approaching a new project, most of the woodworking actions needed for it, you have done on other projects. By recognizing this, you create the mindset you need to build something that seems intimidating such as a door.

I hope you enjoy and find the video helpful.

Your friend in the shop-

Todd A. Clippinger

Share the Love - Share the Knowledge
Thanks Doc - I have been dying to get out more videos. I have a lot to share!
 

Attachments

#6 ·
Demystifying Door Construction

Constructing doors can seem intimidating. In this video I share with you how I built a custom door and demystify the process of door construction.

Watch Demystifying Door Construction

Fixture Wood Stairs Wood stain Floor


One of the ideas that I really want to impress on everybody is this: Don't be intimidated by new projects. When approaching a new project, most of the woodworking actions needed for it, you have done on other projects. By recognizing this, you create the mindset you need to build something that seems intimidating such as a door.

I hope you enjoy and find the video helpful.

Your friend in the shop-

Todd A. Clippinger

Share the Love - Share the Knowledge
Good stuff Todd.
Love the skinned OSB trick. I had never thought of that.

Steve
 

Attachments

#7 ·
Demystifying Door Construction

Constructing doors can seem intimidating. In this video I share with you how I built a custom door and demystify the process of door construction.

Watch Demystifying Door Construction

Fixture Wood Stairs Wood stain Floor


One of the ideas that I really want to impress on everybody is this: Don't be intimidated by new projects. When approaching a new project, most of the woodworking actions needed for it, you have done on other projects. By recognizing this, you create the mindset you need to build something that seems intimidating such as a door.

I hope you enjoy and find the video helpful.

Your friend in the shop-

Todd A. Clippinger

Share the Love - Share the Knowledge
Steve - As a remodeling contractor I have seen so many doors and how they are constructed that it seemed like a reasonable answer to what the core should be.
 

Attachments

#8 ·
Demystifying Door Construction

Constructing doors can seem intimidating. In this video I share with you how I built a custom door and demystify the process of door construction.

Watch Demystifying Door Construction

Fixture Wood Stairs Wood stain Floor


One of the ideas that I really want to impress on everybody is this: Don't be intimidated by new projects. When approaching a new project, most of the woodworking actions needed for it, you have done on other projects. By recognizing this, you create the mindset you need to build something that seems intimidating such as a door.

I hope you enjoy and find the video helpful.

Your friend in the shop-

Todd A. Clippinger

Share the Love - Share the Knowledge
Todd,

Great video… Tips… Techniques…

COOL use of OSB!

COOL use of BONDO!

You really made it look Simple!

Thank you very much!
 

Attachments

#9 ·
Demystifying Door Construction

Constructing doors can seem intimidating. In this video I share with you how I built a custom door and demystify the process of door construction.

Watch Demystifying Door Construction

Fixture Wood Stairs Wood stain Floor


One of the ideas that I really want to impress on everybody is this: Don't be intimidated by new projects. When approaching a new project, most of the woodworking actions needed for it, you have done on other projects. By recognizing this, you create the mindset you need to build something that seems intimidating such as a door.

I hope you enjoy and find the video helpful.

Your friend in the shop-

Todd A. Clippinger

Share the Love - Share the Knowledge
Nice video Todd…good to see you again. I have used bondo in projects before. I had a very large entertainment center which I have repurposed twice!! In doing so, I have had to break apart sections that were glued together. Of course the wood splintered in those areas. Bondo filled in the gaps and when it was painted even I couldn't see the repair. Take care and keep up the good work!
 

Attachments

#10 ·
Demystifying Door Construction

Constructing doors can seem intimidating. In this video I share with you how I built a custom door and demystify the process of door construction.

Watch Demystifying Door Construction

Fixture Wood Stairs Wood stain Floor


One of the ideas that I really want to impress on everybody is this: Don't be intimidated by new projects. When approaching a new project, most of the woodworking actions needed for it, you have done on other projects. By recognizing this, you create the mindset you need to build something that seems intimidating such as a door.

I hope you enjoy and find the video helpful.

Your friend in the shop-

Todd A. Clippinger

Share the Love - Share the Knowledge
Thanks for sharing Todd, I subscribe to your channel and learn a lot from your videos
 

Attachments

#11 ·
Demystifying Door Construction

Constructing doors can seem intimidating. In this video I share with you how I built a custom door and demystify the process of door construction.

Watch Demystifying Door Construction

Fixture Wood Stairs Wood stain Floor


One of the ideas that I really want to impress on everybody is this: Don't be intimidated by new projects. When approaching a new project, most of the woodworking actions needed for it, you have done on other projects. By recognizing this, you create the mindset you need to build something that seems intimidating such as a door.

I hope you enjoy and find the video helpful.

Your friend in the shop-

Todd A. Clippinger

Share the Love - Share the Knowledge
gbear - Then you know the deal with Bondo!

Mario - That is MOTIVATING! Thanks!
 

Attachments

#12 ·
Demystifying Door Construction

Constructing doors can seem intimidating. In this video I share with you how I built a custom door and demystify the process of door construction.

Watch Demystifying Door Construction

Fixture Wood Stairs Wood stain Floor


One of the ideas that I really want to impress on everybody is this: Don't be intimidated by new projects. When approaching a new project, most of the woodworking actions needed for it, you have done on other projects. By recognizing this, you create the mindset you need to build something that seems intimidating such as a door.

I hope you enjoy and find the video helpful.

Your friend in the shop-

Todd A. Clippinger

Share the Love - Share the Knowledge
Great Lookin Job
 

Attachments

#13 ·
Demystifying Door Construction

Constructing doors can seem intimidating. In this video I share with you how I built a custom door and demystify the process of door construction.

Watch Demystifying Door Construction

Fixture Wood Stairs Wood stain Floor


One of the ideas that I really want to impress on everybody is this: Don't be intimidated by new projects. When approaching a new project, most of the woodworking actions needed for it, you have done on other projects. By recognizing this, you create the mindset you need to build something that seems intimidating such as a door.

I hope you enjoy and find the video helpful.

Your friend in the shop-

Todd A. Clippinger

Share the Love - Share the Knowledge
I always enjoy your vids Todd. Keep on keepin on.
 

Attachments

#14 ·
Demystifying Door Construction

Constructing doors can seem intimidating. In this video I share with you how I built a custom door and demystify the process of door construction.

Watch Demystifying Door Construction

Fixture Wood Stairs Wood stain Floor


One of the ideas that I really want to impress on everybody is this: Don't be intimidated by new projects. When approaching a new project, most of the woodworking actions needed for it, you have done on other projects. By recognizing this, you create the mindset you need to build something that seems intimidating such as a door.

I hope you enjoy and find the video helpful.

Your friend in the shop-

Todd A. Clippinger

Share the Love - Share the Knowledge
thanks Todd good to see you again ,another great video and thanks again my friend.Sage is looking good too
 

Attachments

#15 ·
Demystifying Door Construction

Constructing doors can seem intimidating. In this video I share with you how I built a custom door and demystify the process of door construction.

Watch Demystifying Door Construction

Fixture Wood Stairs Wood stain Floor


One of the ideas that I really want to impress on everybody is this: Don't be intimidated by new projects. When approaching a new project, most of the woodworking actions needed for it, you have done on other projects. By recognizing this, you create the mindset you need to build something that seems intimidating such as a door.

I hope you enjoy and find the video helpful.

Your friend in the shop-

Todd A. Clippinger

Share the Love - Share the Knowledge
Thanks for the kind words on my videos, it always motivates me to do more. There is always the conflict of time though since I run my own business, it does't leave much left over for the family or other interests such as sharing woodworking knowledge (as much as I love doing that.)

Both of our dogs died last summer. The last video I did was 10 months ago, at the end of that video Bella came in which was just a week before we lost her. It seems fitting that in this video our new girl Sage came in as an introduction. We have only had her a couple of weeks but we have bonded deeply. She is a sweet dog and well behaved.

Shoe Dog Vertebrate Leg Dog breed
 

Attachments

#16 ·
Demystifying Door Construction

Constructing doors can seem intimidating. In this video I share with you how I built a custom door and demystify the process of door construction.

Watch Demystifying Door Construction

Fixture Wood Stairs Wood stain Floor


One of the ideas that I really want to impress on everybody is this: Don't be intimidated by new projects. When approaching a new project, most of the woodworking actions needed for it, you have done on other projects. By recognizing this, you create the mindset you need to build something that seems intimidating such as a door.

I hope you enjoy and find the video helpful.

Your friend in the shop-

Todd A. Clippinger

Share the Love - Share the Knowledge
Favorited! Thanks for sharing, Todd! Over thinking…that's what I do!
 

Attachments

#17 ·
Demystifying Door Construction

Constructing doors can seem intimidating. In this video I share with you how I built a custom door and demystify the process of door construction.

Watch Demystifying Door Construction

Fixture Wood Stairs Wood stain Floor


One of the ideas that I really want to impress on everybody is this: Don't be intimidated by new projects. When approaching a new project, most of the woodworking actions needed for it, you have done on other projects. By recognizing this, you create the mindset you need to build something that seems intimidating such as a door.

I hope you enjoy and find the video helpful.

Your friend in the shop-

Todd A. Clippinger

Share the Love - Share the Knowledge
Another great educational video! You make it look so easy. The OSB core and the Bondo were 2 new "tricks" for me. Thanks for sharing.
 

Attachments

#18 ·
Demystifying Door Construction

Constructing doors can seem intimidating. In this video I share with you how I built a custom door and demystify the process of door construction.

Watch Demystifying Door Construction

Fixture Wood Stairs Wood stain Floor


One of the ideas that I really want to impress on everybody is this: Don't be intimidated by new projects. When approaching a new project, most of the woodworking actions needed for it, you have done on other projects. By recognizing this, you create the mindset you need to build something that seems intimidating such as a door.

I hope you enjoy and find the video helpful.

Your friend in the shop-

Todd A. Clippinger

Share the Love - Share the Knowledge
Thanks for sharing….
Not only the video & motivational confidence booster….
But of your loss and new found friend!!!
 

Attachments

#19 ·
Demystifying Door Construction

Constructing doors can seem intimidating. In this video I share with you how I built a custom door and demystify the process of door construction.

Watch Demystifying Door Construction

Fixture Wood Stairs Wood stain Floor


One of the ideas that I really want to impress on everybody is this: Don't be intimidated by new projects. When approaching a new project, most of the woodworking actions needed for it, you have done on other projects. By recognizing this, you create the mindset you need to build something that seems intimidating such as a door.

I hope you enjoy and find the video helpful.

Your friend in the shop-

Todd A. Clippinger

Share the Love - Share the Knowledge
Excellent instructions
 

Attachments

#20 ·
Demystifying Door Construction

Constructing doors can seem intimidating. In this video I share with you how I built a custom door and demystify the process of door construction.

Watch Demystifying Door Construction

Fixture Wood Stairs Wood stain Floor


One of the ideas that I really want to impress on everybody is this: Don't be intimidated by new projects. When approaching a new project, most of the woodworking actions needed for it, you have done on other projects. By recognizing this, you create the mindset you need to build something that seems intimidating such as a door.

I hope you enjoy and find the video helpful.

Your friend in the shop-

Todd A. Clippinger

Share the Love - Share the Knowledge
Thanks Todd for the great suggestions. And so timely.

Creating your own stock from OSB is a great idea and solves the vexing problem of wood movement. I've avoid projects that need long pieces because they always move on me. You've given me something else to try.

Thanks and keep up the vids.
 

Attachments

#21 ·
Demystifying Door Construction

Constructing doors can seem intimidating. In this video I share with you how I built a custom door and demystify the process of door construction.

Watch Demystifying Door Construction

Fixture Wood Stairs Wood stain Floor


One of the ideas that I really want to impress on everybody is this: Don't be intimidated by new projects. When approaching a new project, most of the woodworking actions needed for it, you have done on other projects. By recognizing this, you create the mindset you need to build something that seems intimidating such as a door.

I hope you enjoy and find the video helpful.

Your friend in the shop-

Todd A. Clippinger

Share the Love - Share the Knowledge
Todd! Great video! This came just in time. My wife and I just bought our first home. I have a whole set of kitchen cabinet doors to make to update the kitchen a little. On top of that, the front door is a little outdated, and I was thinking about trying to make one. I'm assuming these same principles you covered in the video are valid for exterior/front door as well?? (maybe not) - at any rate, thanks for the great video! I would have never thought of sandwiching OSB like that! Very cool!
 

Attachments

#22 ·
Demystifying Door Construction

Constructing doors can seem intimidating. In this video I share with you how I built a custom door and demystify the process of door construction.

Watch Demystifying Door Construction

Fixture Wood Stairs Wood stain Floor


One of the ideas that I really want to impress on everybody is this: Don't be intimidated by new projects. When approaching a new project, most of the woodworking actions needed for it, you have done on other projects. By recognizing this, you create the mindset you need to build something that seems intimidating such as a door.

I hope you enjoy and find the video helpful.

Your friend in the shop-

Todd A. Clippinger

Share the Love - Share the Knowledge
darkemer - The short answer is yes. But, I gotta tell ya, as a remodeling contractor I have seen so many wooden exterior doors, repaired and replaced them, I just have to throw it out there that a steel or fiberglass door will hold up a lot better to weather exposure. It would be better to spend your time replacing it with a whole new pre-hung unit than building a door yourself.

Take note that an interior door is 1-3/8" while an exterior door is 1-3/4". This means that if you use a 1" core, the solid wood skin starts getting thicker and the issue of wood movement really starts to become a problem. I don't like the faces to go any thicker than I did for this particular door, which is an interior door.

If you build an exterior door, I recommend going to a thicker OSB material which is rim board material, it is 1-1/4" thick (that is the outside rim of the house that all the floor joists connect to.) That means you only have to go another 1/4" each face to achieve the 1-3/4" standard thickness of an external door. But once again, the thicker the wood face, the higher the risk of wood movement.

Rim board material comes in 20' lengths, and widths of 9", 12", or 16". It is normally found at a lumber yard geared to the contractor. Locally, the 12" material costs $64 just for an idea of cost.

I once made a wooden door from reclaimed beams from an old factory on the east coast. As you can see, the building has quite a bit of exposure. It is located in Ucross, Wyoming which goes from severe dry heat in the summer, over 100°, to subzero temps in the winter, -20° to -30° is not uncommon.
Snow Sky Building Window Tree


The wood was sliced down and glued up about 1/4" thick on the core since it was spec'd out to be soda blasted to make it more rustic. Notice how big the crack is compared to my car keys just after 4 months, and there were several of them. At the time of this picture, at Thanksgiving, the door had still not gone through the coldest cycle of the year which hits in Jan & Feb.

Sleeve Wood Finger Beige Metal


While I can understand the eagerness to take on the challenge of building a door, doing the interior doors is less critical than constructing an exterior door. Interior doors just don't take the environmental beating that an entry door does. While I hate to discourage anybody, that is my recommendation as a professional.
 

Attachments

#23 ·
Demystifying Door Construction

Constructing doors can seem intimidating. In this video I share with you how I built a custom door and demystify the process of door construction.

Watch Demystifying Door Construction

Fixture Wood Stairs Wood stain Floor


One of the ideas that I really want to impress on everybody is this: Don't be intimidated by new projects. When approaching a new project, most of the woodworking actions needed for it, you have done on other projects. By recognizing this, you create the mindset you need to build something that seems intimidating such as a door.

I hope you enjoy and find the video helpful.

Your friend in the shop-

Todd A. Clippinger

Share the Love - Share the Knowledge
Mark Carroll Photography has a good detail shot of the door and you can see the weathering pretty good in it.

Check out Mark Carroll's album Places of Worship and you will see the first 6 photos are of the Ucross Chapel.

My friend Andy Parent of Iron Ox built the chandeliers and did all the metal work inside the building. He also made the windows in the door I built. (The work I did on this project was under another contractor a few years ago and I do not have the photo documentation of the process that I normally have.)
 

Attachments

#24 ·
Demystifying Door Construction

Constructing doors can seem intimidating. In this video I share with you how I built a custom door and demystify the process of door construction.

Watch Demystifying Door Construction

Fixture Wood Stairs Wood stain Floor


One of the ideas that I really want to impress on everybody is this: Don't be intimidated by new projects. When approaching a new project, most of the woodworking actions needed for it, you have done on other projects. By recognizing this, you create the mindset you need to build something that seems intimidating such as a door.

I hope you enjoy and find the video helpful.

Your friend in the shop-

Todd A. Clippinger

Share the Love - Share the Knowledge
Todd, lost my K-9 buddy in April….......brothers in grief…...difficult to describe. Good vid and thanks….;-j
 

Attachments

#25 ·
Demystifying Door Construction

Constructing doors can seem intimidating. In this video I share with you how I built a custom door and demystify the process of door construction.

Watch Demystifying Door Construction

Fixture Wood Stairs Wood stain Floor


One of the ideas that I really want to impress on everybody is this: Don't be intimidated by new projects. When approaching a new project, most of the woodworking actions needed for it, you have done on other projects. By recognizing this, you create the mindset you need to build something that seems intimidating such as a door.

I hope you enjoy and find the video helpful.

Your friend in the shop-

Todd A. Clippinger

Share the Love - Share the Knowledge
wooded - I feel for you man, it is tough losing them.
 

Attachments

#26 ·
Demystifying Door Construction

Constructing doors can seem intimidating. In this video I share with you how I built a custom door and demystify the process of door construction.

Watch Demystifying Door Construction

Fixture Wood Stairs Wood stain Floor


One of the ideas that I really want to impress on everybody is this: Don't be intimidated by new projects. When approaching a new project, most of the woodworking actions needed for it, you have done on other projects. By recognizing this, you create the mindset you need to build something that seems intimidating such as a door.

I hope you enjoy and find the video helpful.

Your friend in the shop-

Todd A. Clippinger

Share the Love - Share the Knowledge
Thanks for the info, Todd! I appreciate it!
 

Attachments

This is an older thread, you may not receive a response, and could be reviving an old thread. Please consider creating a new thread.
Top