I call this door
"The Patterson"
It is 40" x 84"
It is quartersawn White Oak
The lights are beveled and thermal glass
and the panels are 1-3/8" thick and raised (both sides)


The styles and rails are
quartersawn Eastern White Oak
Here is the original drawing
Installed on the home !!


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Here is an interesting view of the beveled and thermal lites

The panels are a beautiful quartersawn White Oak

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Notice the beautiful medullary rays in the quartersawn panels
Here is the door prehung in a White Oak Jamb
see more below
Notice the beautiful facets of the beveled glass



Below is the history of how this door was made

Each piece of the rough 8/4 lumber was hand picked for figure and grain. It is then placed in a heated room for 2-3 weeks to stabilize before the machining process begins

The moisture is monitored and brought to an average of 9% to 10% to be most stable in the region of Northern California where it will "live".

The pieces are "roughed out" and allowed a few days to settle down and let any tension resolve

The bottom horizontal rail is 11" wide and best made of 2 pcs of 6" vertical grain ...... so that true vertical can be used.... it will cure for 4 days in clamps

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ANY

Image to Enlarge


When you enlarge this pictures you will see that the annual growth rings are so close together, that it is hard to define. This wood is amazing

All of the lumber is bought rough and then jointed to flat on face and the surfaced to thickness.

Then the surfaced pieces are jointed on edge to be made straight and square

The mid vertical mullions are all cut at one time so as to be the exact same length

The mullions are then fitted to length by jointing 3/32" off the bottom rail

I then choose the horizontal mullions and label them for their place in the door

Each ...... and I mean EACH.... mullion is hand fit to its' place in the grand design.

They will now be machined on the sides and the door will be ready to be glued up !!

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ANY

Image to Enlarge

Each piece is pre-glued and then the assembly starts. This door is built from the center out

Here it is just assembled. All of the excess glue is wiped off

And then we actually wash the residual ...... and clean the corners with a toothbrush

The door cures for at least 72 hrs before it can be removed from the clamps.

Check out the medullary rays that appear in vertical grain White oak

Here is a view of the inside of the door ...... just out of clamps.

Here is the quartersawn blanks for the long panels

and we dimensional sand them to the rough thickness

Then they are shaped and then sanded by machine and then by hand

Every molded edge is hand sanded and then the faces are sanded ..... all of this before I trim the door, which is made 1/2" oversize.

Here is a view of the solid 1-1/2" white oak jambs before kerfing for the weather-stripping or sanding

The hinges are mortised and the door is "signed"

The hinge is fitted

At the top, of a heavy door, I place the hinges closer together ...... since most of the weight is carried by the top hinges

Here the door is ready for oil

Here is the first (of four) coat of varnish oil .... just look at the grain !!

Each coat has to cure for 3 days before re-coating

The panels are oiled separately (4x's)
This way the panels and doors are sealed for the inside out .... that's the way it should be !!

Each panel is solid 1-3/8" White Oak and raised on both sides

Here the door jamb receives its' first coat of oil

Here are a few if the beveled and thermal glass units

Here is everything fitted in the door and ready for stops to be hand cut

I make the stops out of the same wood that I used in the doors .... that's why the wood matches .

Here is a close-up of the panels and stops

Because the door weighs 150 lbs I use 2 - 4" hinges at the to 1/4th of the door. All of the weight is trying to pull out the hinge

I use 4 hinges to hold the door. They are solid brass with a lifetime finish. The door weighs 215 lbs in the jamb

Here is a close-up of the jamb with weather stripping. I provide the jamb long so that it can be trimmed on sight for the threshold

Here are the 2 load bearing hinges at the top of the door and jamb


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