The Old Growth Redwood Cypress Door

The Entry Door Drawing

Here is the 40" Entry Door

The Sun Room Door

Here is the completed door

Here are two new doors I have just completed.
One is a beveled glass entry door
and the stained glass door is the Sun Room Door

The Entry Door Drawing
Here is the 40" Entry Door
The Sun Room Door
Here is the completed door

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This is the Sun Room Door

Here is he door with the glass backlit

Here are the panels in the Sun Room Door

The panels are curly grain Redwood with a bird's-eye Redwood center panel

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CLICK HERE
to see how this glass window was made

Here is a picture of the glass lit from behind

Here is a close look at the glass from the front

	This is the Entry Door

Here is the completed Old Growth Redwood	The panels are curly grain Redwood and bird's-eye Redwood in the center panel	It is a 40" wide Entry Door
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Here is another view of the panels	Here is the beveled, thermal, tempered glass	Here is a close up of the beveled, thermal, tempered glass ..... the bevel is very hard to photograph with the white background

This is how these doors were constructed

The Redwood is checked for moisture content and verified that it is dry

I place it in racks in a heated room to equalize the wood. It "cures" for 2-3 weeks in the racks

Here are the major pieces to the two doors.

They will "settle down" for a few days before I start to machine them.

Here are all the smaller pieces to the two doors ...... sized out of the planer and ready to start machining

All pieces get shaped to a profile which I had custom made for many of my "craftsman style" doors

Then each piece get hand fitted .... and refitted .... and refitted

until ..... the boss voices his approval ..... or ..... is it time to play!!!

Here the Sun room door is dry fitted ... such beautiful Redwood

Here the Entry Door is glued up and all of the excess glue is clean by hand

.... and then it is taken one step further ....... and all joints are cleaned with "the bosses" toothbrush!!!

Here is the Entry Door in clamps

The Entry Door will cure in clamps for at least 72hrs

Here is the Entry Door out of clamps

Here is a close-up of the upper half that will have tempered beveled glass, which can now be ordered

Here is the Sun Room door curing in clamps

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Image to Enlarge

Here is the Sun room door
out of clamps

Here is an amazing abnormality in the Sun room mid-rail ..... it is amazing

The entry door glass has been ordered and the sanding begins

Each and every mullion is hand sanded and finished to furniture quality

Here the figured panels are set in the vacuum press for 48 hrs

Here the door ...... which is made slightly oversized ....... is cut to length and width

then ..... the 1-1/2deg back bevel is jointed on the opening edge

Here the door is being bored for the lock set an dead bolt

Here is the Sun room door .... finished sanded

The floating panels are set in for sizing ....... notice the panels are left with room to expand when the humidity increases

Here the Sun room door is being oiled with its' first of 4 coats of varnish oil. It will cure at least 72 hrs between coats

curing ...... !!

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Image to Enlarge

Here is that beautiful mid rail

Here the entrance door is finish sanded before oiling

Here the entrance door being bored for the lock set

Here the doors are mortised for the solid brass hinges and "signed"

Here are the panels being oiled

The panels will each be oiled with 4 coats of my "varnish oil" before they are placed in the door.

Here are the oiled panels for the entrance door .... they are tiger stripe curly grain VG old growth Redwood

Here is a new toy called a dimensional sander that allows me to sand and size highly figured wood to use for the panels in my doors

Here are the oiled bookmatched panels for the Sun room Door .... they are quilted old growth Redwood

The stops all soak in this "trough" for at least one hour ..... 3 separate times

Here are the stops after soaking

Here is the Entrance door finish sanded, bored for hardware, ready to oil

Here is the Entrance door absorbing its' first coat of my varnish oil

Most of our exceptional fabricated glass products have been constructed by Thermal Sun Glass of Santa Rosa, CA

here is a view of the old growth Redwood end grain ...... there are up to 5o growth rings to 1 inch

This is amazing ........ this is a cutoff of the end of one of my boards ....... please notice ..... this was not "sawn" but rather this tree was "chopped" down decades ago !!

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Image to Enlarge

Here are the stops laid out and matched for color

Then Each Stop is hand fit and cut

That's why the fit looks like this !!

Here is the tempered, beveled, and thermal glass

CLICK HERE
to see how this glass window was made

Here is a view of the door with the panel stops, cut to fit

Then the 36 stops for the glass are marked, fitted and cut.

Here is a rendering of the stained glass to go in the Sun room door

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Image to Enlarge

Each panel " floats in place suspended by little "space ball" spacers

Then the panel is caulked from the outside with a special (flexible) siliconized latex, that turns clear (but not seen) and remains flexible, so that the panel (which is alive) can grow and shrink with the seasons.

A close-up of the installed panels.
Note: the stops are set with stainless steel fasteners so they won't "bleed out" rust over time.

Here the Sun Room door stops are sized and precut ......... awaiting the completion of the stained glass.