The Winston Knolls Interior Redwood Doors

This is a set of 6 Interior Doors
known as The Winston Knolls Door Project
They are all about 80" tall and vary in width.
They are each Old Growth Redwood
and have Curly Redwood Panels

Here are all 6 doors together ........ they will grace the downstairs doors
Click on Any Image to Enlarge

Here is the downstairs bath door

a view of the upper panel

and the lower pane. They all come from the same planks from top to bottom ...... of course !

Here is the Study door

with bookmatched upper panels

and bookmatched flame burl panels with a "Redwood "glass wood" divider

A view of the lower half

this is a piece of of Redwood Burl

Here is the guest bedroom door

and the upper panel

and bottom panel have this lovely Red stripe

and the Utility Room

Here is the upper panels

and the bookmatched lower panel

This is the camode door off of the kitchen

what a beautiful panel (upper)

and a bookmatch from top to bottom

Here is the left side of the hall closet doors

and its" upper panel ......

and lower panel

and ....... the right side of the closet doors pair

the upper panel is beautiful

as is the lower panel.
please note how the molding matches in each of the closet doors.

Each piece of molding is hand cut and fitted

piece by piece .. cut by cut

ALL of the panel wood came from the same Old Growth Redwood Tree

it took 3 days to cut and fit the raised molding

and it was worth it !!

Here is the provenance of the making of these beautiful doors

each piece of this lumber in these doors came from the same salvaged log and I marked them so that 2-3 years later I would remember where they came from

Notice the fine grain on the boards. There are 40+ growth rings per inch ......... that means the giant tree took 40 years to grow in inch in the radius ..... many of these trees are over 1000 years in age

Here the rough lumber is flattened and planed

each piece of this lumber in these doors came from the same salvaged log and I marked them so that 2-3 years later I would remember where they came from

Here the rough lumber is flattened and planed

The wood is surfaced from 2" to
1-5/8"

Quite a bit of lumber in 6 doors

Here are the styles

Surfacing the wood.

Most interior doors are 1-3/8"
These doors will be 1-5/8" thick and solid

Here I'm matching up the styles.

Here are the pieces laid out

and then fit to perfection

Then we glue all our doors with exterior water proof glue

All joints are cleaned ...... and corners with a toothbrush

Here is a door glued up and in clamps.

s. Where they will stay in clamps for 72 hours. Several glued up and clamped door

Doors freshly out of clamps and ready to be sanded and finished.

a door in the process of being clamped

This is part of the master bedroom door.

More doors is clamps

Here I am fitting the master bedroom door.

Here is the master bedroom door being glued up.

Here is the master bedroom door being hand sanded.

Every door is hand sanded.

Here is the master bedroom door out of clamps.

Here is a door being run through a dimensional sander.

The interior doors that are being run through the dimensional sander.

The master bedroom door being run through the dimensional sander.

Here is the bedroom door ready to be trimmed.

Here is the door being trimmed

Here we are resawing the curly red wood to be book-matched for burl panels in these doors.

Here are panel stock being surfaced.

Here is panel stock being run through the dimensional sander.

Here is the booked matched curly redwood coming out of the dimensional sand



This is a photo of panels being glued up.	and wrapped tight for the vacuum press.	Glued up and wrapped panels being vacuumed pressed for three days

These are the ends of the salvaged lumber indicating that all the lumber came form one tree.	Here are the panel cores being laminated.	Laminated panels in clamps and drying

Here are the panel cores out of clamps.	The panels are all edged with old growth redwood.	Here the panels are being edged.

Here the panels are being edged.	Here I'm sorting out the match booking.	More curly redwood being sanded.

Laying out the booked matched panels.	Gluing up the booked matched panel faces.	another photo of gluing up booked matched panel faces.

There are over 20 panel faces to be glued.	More panel faces being glued up

panel face being sanded.	looks like deja vu all over again	More panel faces being glued up.

Panels just removed from the vacuum press.	More panels freshly out of the vacuum press.	These panels are soon to be shaped and sanded.



You guessed, it more panel stock being glued up.	Panel stock out of the vacuum press.	Panel stock ready to be shaped.

Lovely shaped panels ready to be hand sanded.	a closer look	More panels ready to be hand sanded.

Hand sanding the bevel on the panels	Ready for there first coat of our varnish oil.	Look at that shine!

The long panels are ready now for there first oiling.	The beautiful panels come alive.	Lower panel ready for our varnish oil.

The curly wood comes alive also	The back side of lower panel before oiling.	The back panels first coat of oil.

Wiping off the oil from the panels	the dimensional sander.	Several panels freshly sanded through our dimensional sander.

More panels to go through the dimensional sander.	Hand sanding the panels.	Rebating the edges on the panels.

Another panel having the edges rebated	More panels waiting for their turn at being hand sanded.	A close up look wood used in some of the panels.

another view.	Fine finishing a panel.	More panels ready for oiling.

More panels getting oiled.	More panels getting oiled.