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Here is the completed
Calpella Entry
Door
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The is the original drawing
This was 1 of 4 versions I drew
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Here I overlaid the drawing on the
entry
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Here I overlaid the door on the
entry
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Click on Any
Image to Enlarge
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Here is a close-up of the beautiful "Oyster Shell"
Mahogany panels
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...... another view of the panels.
They are raised on both sides
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Notice the fine grain Mahogany
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These units are beveled glass units which are
tempered and insulated
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Here is the history
of the construction of this entry
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Here is the rough 2" lumber
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All pieces are joined straight and then....
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...... they are thickness planes
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Here the pieces are "roughed out"
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And then each piece is cut to its' exact length and
"dry fit" ....... it's a long process but the finished door
makes it all worth it
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Here is the door, just glued up and in clamps and
the excess glue is wash off ..... over and over
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........ and over
Think we used enough clamps .... our doors will endure the
elements and the tests of time
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All of the corners are scrubbed with a
toothbrush
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and the more clean water and scrubbed again ......
smile !!
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Here the door rested in clamps for at least 3
days
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and the a check for flatness and the sanding
begins
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I join and backbevel the edges
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and the "fire up" by branding iron
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and we sign each door ..... with pride
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here I am mortising for the hinges
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and here ya go !! 4" ball bearing hinges
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Here is the door receiving the first coat of of
varnish-oil
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and the door will receive 4 coats to protect it for
a long time
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Here are the panel "blanks". They are 1-3/8"
thick
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and here are the bookmatched oyster shell Genuine
Mahogany
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Here they are ready for oil
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and here they are being oiled.
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The door cures for at least 3-4 days between coats
of oil. It needs time to cure.
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Here is the door jamb under construction
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Here are the jambs after oiling
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Here is a glass unit. It is beveled and
insulated
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Here are all the "pieces" in their new home
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The panels "float" in their opening so they can
expand and contract
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Here you can see how all the panels
float.
We then cut and fit each Mahogany stop
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.... and the seal under the stops with a
special siliconized caulk which turns clear when it
cures.
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The excess calk is removed after it has
squeezed out.
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