The Entry Door is called
The Carpinteria
It is 42" x 85" x 1-3/4"
It is Old Growth Redwood with
Figured Redwood Panels
The glass ids tempered and insulated Seedy Reamy
and the Eyebrow and Dentil Shelf are Redwood

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Here is the completed door

Here is a close-up of the upper half of
The Carpinteria

Here is another view of The Carpinteria

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The panels are bookmatched flat sawn curly Old Growth redwood

Here is a close up of the Redwood Panels
Nice ..... huh !!

The Eyebrow if bent laminated Redwood

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and the eyebrow "floats "off the door on Mahogany pins

The dentil shelf is attached with stainless steel screws and capped with beautiful pins of Pao Brasil

The glass is tempered and insulated art glass called Seedy Reamy

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....... and here are the Boys !
Here is a view of the drawing on the
front of the house
Here are the dimensions
Here is a drawing of The Carpinteria

Here is the History of how this door was constructed

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Here is the "rough stock" that will make this door
Every piece is cut oversized and the joined straight and then surfaced to thickness
Then cut to exact length
Here are some more pictures of the rough stock

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Here I am cutting the template for the arched top and mid rail
...... and here I am dimension sanding the top and mid rail to 1-3/4" thick
Then I transfer the arc to the pieces
Drill the top piece for the mullions and pre drill and fill the holes with dowels ...... cool trick

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Then I cut the arcs
and you can see the dowels that are left and after planing they will accept machining
The I "smooth" the arc with a 100 year old plane, called a compass plane because the sole is adjustable
Then comes the hand sanding

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Then I fit each piece ... one by one
... know this ..... a perfect joint does not allow the "union" of the woods to fail
and I spend a lot of time making sure that each piece fits .... "just right"
Then we glued up The Carpinteria and remove all the excess glue we can

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... and yes ....... scrub the corners with a toothbrush and clean water ..... then blow off the water with compressed air
Here the door will cure for at leas 3 days
And then we're ready to sand the door. Here Jason is doing all of the scraping first
The we start machine sanding the door all the way down to 220 grit

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And of course ....... hand sand all of the molded edging .... inch by inch
Then I heat up my signature
and place it of the hinge edge
This means I (we are) am proud enough to tell folks who made this piece of fine woodworking

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Not forgetting to sand the edges
and "back bevel" the opening edge
Here is the door ready to be sealed and oiled
Even the inside of the panels and glass gets 4 coats of our varnish-oil


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... yes 4 coats and we wait at least 3-4 days between coats
Here I made templates to mail of to ThermalSun ...... who will make the insulated and tempered glass units
Here are the panel blanks with the Redwood edging being applied
and here are the panel blanks after having the figured Redwood panels glued on

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The panels are being sanded on my wide belt sander ....... they are curly Redwood and bookmatched to each other
Here I cut the arc in the tops of the panels
and the cut the rebates
Here are all 3 panels

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Last step is to chamfer the panel edge ...... just to add another dimension
Here are the panels ready to be hand sanded
and here they are with their first of 4 coats of oil.
There are the pieces that will make up the bent laminated eyebrow

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They are sanded to dimension
The clued in this form and allowed o cure for 4 days
Here is the blank out of the press
Then cut to width and sanded ..... and sanded

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After machining we have a "sneak" preview as ti its' proportions ..... Great !!
Here are the panels .... the dentil shelf .... and the eyebrow ..... all be saturated with our varnish oil.
.......whadaythink ?? ..... not bad !!
Here the glass is being caulked with a special caulk (that turns clear) and will be covered with curved steam bent stops

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Here are all of the stops laid out and precut
Then we caulk the floating panels and clean up any squeeze out
Here the door will lay flat while the caulk cures for 3 or 4 days
... so I start to layout the eyebrow

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The redwood eyebrow will be attached with Genuine mahogany dowels that UI made in shop
Then I layout the dentil shelf placement
and the dentil posts
Then glue the dentil post to the door

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and glue on the eyebrow
The dentil shelf is attached with stainless steel screws but I cap them with wood pins ..... here I am chiseling the diamond
These pins are made from a wonderful reddish wood called Pao Brasil
Here is a close-up of the attached eyebrow

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and here is the door complete
and ........... here is the door complete!!
These are the same at the top of the page
........ enjoy !! ........

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