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Here is the completed Entry Door
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Here is the original drawing
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The styles and rails are salvaged VG Old Growth
Redwood
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Click on Any
Image to Enlarge
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The panels are sawn from large timbers
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The panels are thich veneers that are laminated over
marine ply to achieve stability for such a large
surface
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The end grain of the door frame wood
Please notice how fine and close the grain is
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Here is the
"provenance" of the making of
this door
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Some of the wood came for bridge timbers from the
logging roads in Jackson State Forest
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As the wood is cut, I code it with water paints to
make sure I keep track of the timbers they were cut
from
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I resawed the 6" and 8" to 2" lumber for the door
frames and I resawed the panel "thick veneers" to 3/8"
planks
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Here is the door the frame after glue up being
cleaned .... even with a recycled toothbrush
(mine!!)
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The frame will stay in clamps for three
days
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Here is the panel center which is marine grade ply
laminated together
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RETURN
TO GALLERY
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Then it is edged with Redwood
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and sanded to flush
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Then the ends are capped with Redwood
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The faces are resawn and glued together
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.. then surface sanded
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the veneers are coated with waterproof glue
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then wrapped in protective plastic
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and placed in a vacuum press for 72 hrs under a
constant vacuum ... until glue has cured
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... then we get to unwrap the present !!
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Click on Any
Image to Enlarge
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ahhhhh ....... perfect
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here is the panel ......... it is 1-19/16" thick and
should be very stable for may years to come
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and the we start of by surface sanding the
panel
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Then trim it to width
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and then trim it to length
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here is an end cut of the panel
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The rebate is actually done on my table saw
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and then I chamfered the panels edge
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every thing is hand sanded to a furniture
finish
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and the surfaces are sanded down to 220
grit
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and then oiled ......... with 4 coats of varnish
oil
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look at the wood come to life (again)
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The panel cured at least 3 days between coats of
varnish-oil
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The door frame is finish banded
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and mortised for hinges ........ then
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signed with pride
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......... and oiled
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the frame, too, cures several days between
coats
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notice the richness after 4 coats
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the panel is set into the frame and Redwood stops
are hand fitted
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the panel actually floats inside of the
frame
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and is "bedded" with a siliconized latex caulk that
really seals the panel from the elements
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RETURN
TO GALLERY
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