Door to be built around an octagon window

[Frank Pellow]

I need to build a single door for my workshop which is under construction (see the thread http://www.sawmillcreek.org/showthread.php?t=7769). I figured that there should be a window in the door to cut down on collisions.

So I went look for a small double paned window and the only one I found that seemed appropriate was an octagon shape and it is very wide. See the attached pictures. Anyway, one of my tasks today is to design a door around the window.

[David LaRue]

Frank,

It looks like that window is for a standard wall thickness. If you are set on this window, you could build out the window opening on the outside trim side with wider boards than the existing trim the depth you need to make the back (inside) work, with perhaps an ogeee on it to matach the other trim.

Dave

[Jamie Buxton]

Or you could cut off the inner couple of inches of the frame. You can do it on the table saw. I'd set up an auxiliary fence which is tall enough to lean the window front against, and make the eight passes necessary to cut it off.

[Frank Pellow]

Thanks for the tips David and Jamie.

I have progressed a bit (but not far) with the door. What I did was to cut an octaganal hole in the 15mm rough sawn plywood that is to from part of the door. Here are a couple more pictures.

[Frank Pellow]

I now know how I am going to build the door. The attached pictures show how I am fitting the window into the opening that I cut into the plywood. They are:

1) Cutting a plastic protrusion off the window. This had to be a very careful operation so as to just remove the lip but nothing more. Festool came to my aid once again.

2) The window without the protrusions on the hole that I cut into the plywood.

3) Placing exterior trim around the window

[Dave Shaffer]

Hey Frank?

On that last picture ya have the sticker on upside down :p

[Frank Pellow]

Hey Frank?

On that last picture ya have the sticker on upside down :p

The picture is taken from the top of the door, mate. :p So everything is cool. :cool:

[Jim Becker]

Frank, nice job. But I'm glad it'd not a half-moon shaped window. Some folks might get the wrong idea about the shop! :D

[Frank Pellow]

Frank, nice job. But I'm glad it'd not a half-moon shaped window. Some folks might get the wrong idea about the shop! :D

Next summer, I am going to build a small extension to the buliding an it will house my garden tools. It will protrude out from the building much like the "outhouse" did on the buliding that my grandfather used as his garage and workshop. Maybe I will put a half moon in the door of the extension; thanks for the idea. :D

[Mike Scoggins]

Frank/Jim,

I had the exact same thought about the half-moon window. If it were me, I couldn't resist. I think I would have a half-smile on my face every time I walked by. ;) Go for it, Frank!

Mike

[Steve Stube]

Very fancy Frank.

BTW, I think it is a half-moon only if the door is closed.

[Steve Clardy]

Looking good Frank.
Where theres a will, theres a way.

Steve

[Chris Padilla]

Frank,

It is interesting that the window has a specific direction. Why is that?

[Frank Pellow]

Frank,

It is interesting that the window has a specific direction. Why is that?

Darned if I know. :confused: I assume that is has something to do with the internal structure and I am not about to take the thing apart in order to find out.

[Steve Clardy]

Darned if I know. :confused: I assume that is has something to do with the internal structure and I am not about to take the thing apart in order to find out.
With a sticker on it telling which is top or bottom of window, tells me that it should have a WEEP hole on the bottom. A hole for moisture to escape if moisture does get in. Most all vinyl windows have these holes.
Steve:)

[Frank Pellow]

With a sticker on it telling which is top or bottom of window, tells me that it should have a WEEP hole on the bottom. A hole for moisture to escape if moisture does get in. Most all vinyl windows have these holes.
Steve:)

Sounds like a great theory Steve. But, I just checked the window very carefully and could not find such a hole. I also checked all the other 7 sides just in case someone (like me) screwed up the label and I couldn't find any holes there either.

[Chris Padilla]

Frank,

You better put a hole in it... :D hehehe Maybe you sliced it off with your judicious use of Green 'n Black.... hehehe :D

[Frank Pellow]

Except for some interior trim and some closing/locking hardware, the door is finished and has been hung. By the way, it weighs 104 pounds and is almost 4 inches thick.

The following pictures are attached:

(1) The back of the door showing the installation of 1.5 inch cedar support, and 1.5 inch solid foam insulation. The cedar is ripped from boards taken from my 25 year old deck. Most of the boards were still in good shape.

(2) The interior surface is 1/2 inch good-one-side fir plywood.

(3) Side view showing multi-layers of the door.

(4) The door has been hung. Note the bolts to support the weight. In spite of the weight, the door swings quite easily.

[Jim Becker]

That's not a shop door...it's a VAULT door! Nice job, Frank. Looks great!

[Chris Padilla]

Frank,

The door should outlast you! :) What is that circular, tan-colored contraption that looks like it could mar your nice door if opened judiciously?

[Frank Pellow]

Frank,

The door should outlast you! :) What is that circular, tan-colored contraption that looks like it could mar your nice door if opened judiciously?

I am expecting the whole shop to outlast me :( :) :( :) :( :)

The tan contraption is the vent for the propane space heater. I will build a door stop to protect the vent (and the door).