Currently, my “office” door is just a large archway off of the kitchen. Because of other logistics (see attached pictures), a bi-parting door seems to be the best option. While on vacation last week, there was a set of bi-parting doors in our hotel room that I took some rough measurements off of. However, I’d like to get some advice before I get started, just make sure I’m not missing anything.
1. Wood selection
Based off my measurements and design (fixed plantation shutter style doors), each door is roughly 8.5’ tall x 22” wide x 1.5” thick, which I estimated to be about roughly 40 board feet (on the high side). I’ve seen basswood is often used for plantation shutters because it’s very light, and at 40 board feet, that’s almost 100 lbs per door. However, my kitchen cabinets looks to be some sort of cherry (either stained or actual cherry), so I thought that might be nice too.
2. Door design
The stiles will be roughly 8.5’ tall, and I planned them to be 4” wide. The rails will be 14” wide and 8” tall. The width of the stiles and the rough dimensions of the rails came from what I saw on doors in my hotel room, and the 8.5’ height is based off my door frame. I’m not sure if there are dimension/proportion guidelines for sizing stiles and rails, so I wasn’t sure if the stile width was appropriate given the 8.5’ height?
Screwing up mortise and tenon on such large pieces of wood could be costly, so I was thinking of doing bridle joints for the door frames because it’s simple and within my skill level. My only concern is would that be strong enough considering how heavy these doors are?
It would be really nice to get the kind of hardware that’s nice enough to be exposed. But I haven’t found any for less than $250+. So, instead I’m looking at hardware like this:
8-Foot Trolley Track
And then covering it up with some crown molding (again, similar look to my kitchen cabinets). I know April Wilkerson did a barn door project where she made her own rails, but I’m not sure I want to go that route. These doors will probably take me long enough to build, not sure I want to add building rails to that.
I’d appreciate any advice, input, or “gotchas” anyone might be able to provide!