An Exterior Door Project

[John TenEyck]

I built this exterior door and frame for a friend of a friend.

https://lh3.googleusercontent.com/2mT_ACYb7uH2Q14YnV677hA6j54FeStjVsBRMPyEnmD9LuuwJo rFxfgpUT2w59GfiTRmTbNJ6RZcSpGfo81TBRATyJwmZb1eMBNf iJOLUm8fpTjs_xa7YPEt8KRWCTP_Fysp8MnYO4g_-e91GKU3I-yQziOqFoFhbtMQGg2MIK5VoPkDwUdBFIUvLBaQnuWV3ZIG1Zfb HZFdAeSIvcWJgO7BhlWHHA9GlCoFgWzcp8qfZqEOX3z8sWU01_ apAZ6uGsKrPFl1jeGEjDnLn3F0SlxH5Fir6jxzke9tCSrIln-EVTXZxyySBn-OiepQPC4GoCD7NxgI6rZNJnRuGJWGbFLNkYVzr-s3WPG2zHzUh2pzoJA7N-rgsYZfHH5jeSwBV-j1vu1XssyJEfpDdGNpyW3K4uPT-MNK7Zuhiw6sKK54C3zGdJjqmjxbDd9xJVe8J2sV-aMTnUUVnAaTKA9lm2gfhFmMe2ovNshTEGJixXAm2ofCkFoCezM 7_EwZLfCEEHs8pTqeOexCvyswODu-GJBNVjCZICwNqr72p5yeQiYAaQ2LnKOxrD21LECsapmzQzq0xx GNk1O4ITtvQnV5WoCnjEGldp25oyqmEZntuD7EMk6G6FuzsoCd l0h-O193uEXbDqjnyezEc9vdmgW7w7rbJxpCaHxU48Xf8Q47hlc=w4 71-h628-no

It's 38" x 84" x 1-3/4". The 3/4" thick raised panels are independent inside and out so each can move independently with the seasons.

https://lh3.googleusercontent.com/TCUPJLyeUcxe0iEqV-6om_Zour9FKgAdzsPTBfqrIuItp1Hj_GyeC7fDeQ5kMv0EpRyM mxsxX_FjMuGR4FOPlcLvUmvnoJMi8h9aqOi9TVUI26ZG2gwJNT BZE-c0P1CkNBBS1fCaIGW_4z50AugCJs2TBF6u0NXz_TGmo_ducra1 Gi3gqltZr7uH_mEAI7vbi2AoI4o39DgWdcGkYHQF5BbkWfLS36 qhHmpL7vYbUgizDb_SA_LNUTFpw3_gkO9kicdfwhSlxrEeEs7-U1EuG9NR9FlZZnOIyE-bDLdxj2tqU8qoJOskUcqgg99FQnX2_xSfL8kjv-B9PpSIlYPErw6kwZwLjM9aSsSajw0I8zPZhvoRWSPooOOgRXi2 q6jG-W_J4oj4UP3vejnncER0RvGCLAkpB4oFBYcTBa5W5Z55mISUy_a oci5pW2qw8oZpgPGFjAblH7qtaOxznLHLpjQH2b1W8n9yuDpcX 6WLty6mQ0WtyCCjzwK1tOTFcU7ZLvNp4IrdlVYPrqYDqdSUXyt ns3KuynS6LkEflZIj1ND1BpgkLmZqHXkVt7tjnSAmX6FkuoJ4d iYQI6iUG1sSUKpHFIGnhtAPgiVaahBfb4Ll_V_EDsWslW54ip2 _mI7MdVIxpvSUje0k0hgxOQA1daAYtlFUyXBfIiziQIdBSlg=w 418-h314-no

The lockset is from Craftsmen Hardware Company Ltd.. The escutcheons are hand hammered copper; the deadbolt and latch assembly are Baldwin. Very nice stuff.

https://lh3.googleusercontent.com/7TznaStFK2UqsgopMutcWvrCHUb0Ipf3DDiZ6xn_v0_2g06Da9 dEO_J401Hr5afoFLDYSnORdVpPR8E3Mhyl3UN7vI5lDlsYvc64 BI-7VQKwXzQ681h06YXQt8h3Z8kVuWwmXc0Nx4ANpD0vTzvDdRGZ6 WdGM4AaeZbVv4crXEy26E4I99jgJrtc1r89epdWgY-t5uEYf6T8YAi9rMe0zUxXkA__QQHpTyuTRWueFd6uq9tv9B1Fi UOc4H_I-WEWL3dDdYswAdQGgrXK5PcGWk4S2I_n1BEcVQdeiQyuiIdTsgt L7eGg-Oc_DA-dbMzBYgnl6E_Abav1E-YX_k9qaPNWVSGjtXeBKpVVm0xVlQy5nCo8NGsyVIw6WH4y41wU UqTcCL5SApVnXW06LoEhqtiRAx1Mn1xeU7X4CwdhMqf7Vv2_6r tBPQbi1lCleE3Irn-AFKhH5wVJpqws1eSgIzcBW6drUTQfwwRM1XlqwiHkQ0DAA9rRG RYP7W3PCSnGAHImCY__sTxL6R67Gm2mczjY_AsYcGNLbLW7FSa rghzyDEQi4ANcyOfOm7GzHappx2EPZ94u7syg1s3vDj3Vybu2X VImW6DHJjo26B4jMqiwKJ-Nk9GAb6wdsjIq_qv2wA2ckWrVjRJEej2Pgj5TMMkblFMN6NN29 WxcvXL_Vh8=w471-h628-no

I used Q-Lon weatherstripping around the perimeter of the door frame and a hidden bottom seal that fits to an ADA compliant sill screwed to the concrete threshold. My pro friend felt that was the best solution for dealing with the threshold which runs downhill on the lock side about 1/4" compared to the hinge side. I think it gives a nice, clean look compared to an adjustable sill.

https://lh3.googleusercontent.com/nYQ3KlC9A-GgpzuMtB5F94supcEnfkXzXUNT7duXp2bbTQbXv_wKP5AbeM6E aCyqf5MvNE4WcfpbzU4NUoYVcK_gPNDBkPLXddmmw8LeZaZVoX CpbHX8Gqd1bKy8D7uDJv0oQ-ML7lnNTmzcuh42izNNdd66-qp2ukZeLszZuZOT2aF5RoOeQe5XjaXchQOuprZUIwM3t7ePtFs Uo-Rpc1s4Sa4aEW05gj6v1q4iL3oTH8Z0CxTDlu1RrKVGaeNGFDkl 6w3SrjdR2mwDq7ql7LUlqahWI-c5-ZS9k0LIw2pWIo9umrSnzkocz2Yf-qfHXbxcNWZseSQoxrc013a7XB_x0bHtzH2IR-NZYIEz-ckTDzrNVfppQcf_aJs9luKVxFxOAo8pY9qb_HMoexHxjx33W0O GoywmPSiKTXoVBCgH_B_Aym1m9K9R4XAL-WtchnP3dk2s1zPI4TSnU2g4l-_JjS76jWi62Qx6syfCG2L25RklxFOB1EqLy_uyvwVmxQt6R538 n0Jr5YdQEDcOpX_sZVMhyvCf7UYPnMx3OwBF2xXE8vQngSEfO6 IsJnPmuU2QM9JwK1vjdRsgfOEJE7rMYDBoHF-lAtXx50LNzCIGfzoxx1ODpEWI-rcwzBuS6Oa9_FOh98rpYavfoMg8SuPrzX6oIcaX6uXkRfIzl54 =w838-h628-no

The bottom of the frame and brick mold were coated with 5 minute epoxy before we set them in place to help protect them against the weather. This door faces due West and gets direct exposure to the elements.

The door is a LVL core with Sapele skins and is finished with Cetol Door and Window finish, done with a brush. The panels are removable from the inside for maintenance or if they ever need to be replaced. Rather than seal them into the frame with silicone to keep water out, which would make removing them pretty difficult, I omitted the silicone and drilled weep holes in the reveal of the bottom molding. I figure those can be cleaned out as needed with a pipe cleaner. Time will tell how this all works out. At this point, the owner is pretty darned happy with the new door. This is what we replaced:

https://lh3.googleusercontent.com/NP6YpcRTlfYhRPSsz5mKsqkkZCYNJJ3rh8M4z3BPZoiQb0V0m0 Ho1Gl5cVcUNnKk_HsdaEdcarsNzd28m9JNRn7TfuF1XyP79T0b W7vsnRWx9XNKc1uNMviYroCe1UON936_IbDeA6OtUxw4UxoN9L urNMDVu3JsumCRxA9fR4OJzo8roRMWyEfo-ZV5Vhirc_28Zru2p9o1hJVaZ5MvUG-bYdOzc93K5RXjdTb4Y0A2xRSZZmdFOfAOgBS9yWmD355AbB5J5 HWyYQNnNGyIQn54YXSEbZH-GvQ0Ww2MdfLJKvf1Nt4mWyC4W4DI3KSCd6UfsbWDG3pIBCW_za tJu8nRGT_tTTIGxZA9F4o2aXLJ49nnp1DytEq3lSmPrT6uyemD kMJQHQTf-yDin3fbuY6H1NmTABBv_0gKp1n0dmv3qNeARh-DAzkEkPM88xL9-tuH_ERefePVsyuZdHaz_Rw1fUKhIOMAQnBKWyOArc89IHUPiaG VoDkdpdiD6m5UfcEJonF6MlAK83Tz-ELLgq_JvgwCDaZ0OPGk84ajKA5_fVmp-kQjXrl2bL3ygxSLEbQXyEtdo4iYA-tf6x2QDsLRkGlqb9HoOdbLWJdZ3n4Q3u-w7zgztxsx8NxHv7Rzxi_rsLg2EDyHkoPbUjC_OgLDxwYuI1EwJ M2E9MBs_UI=w273-h365-no

John

[Jim Becker]

Really beautiful!

[Darin German]

Stunning. A truly beautiful door. Good job!

[Mel Fulks]

So well thought out. I especially like the moulded frame, existing situation is deserving of it. I would prefer a four panel door for better verticality. Think it would be more in keeping with the stone work. But sometimes they won't listen! Old door looks like a most inappropriate replacement .

[George Bokros]

Beautiful door. Great work John.

[Andrew Hughes]

Super nice John thanks for sharing.

[Jason Roehl]

Okay, I just went to the National ADA Symposium a month ago, so I have to ask--why did you use an ADA-compliant threshold?

Beautiful door.

[Art Mann]

I am impressed!

[John TenEyck]

Okay, I just went to the National ADA Symposium a month ago, so I have to ask--why did you use an ADA-compliant threshold?

Beautiful door.


I used the ADA compliant threshold and automatic door bottom because it looks better than an adjustable sill and would make it easier to walk over. The concrete threshold is too high and wide to step over as you enter or leave the house and you are pretty much forced to take a step on it to pass through. The low profile of the ADA compliant sill makes that easy to do.

John

[Metod Alif]

I met John about a year ago, thanks to this forum. We became good friends. I have seen this door 'gestating' in his workshop. The attention that he pays to his work is truly inspirational. I also have been watching the installation process (only a few houses from mine). The design was customer's but but the rest was John's. The door not only looks great but also operates flawlessly with a nice thump when it closes. The customer is beaming.
John, great job.
Metod

[John TenEyck]

[QUOTE=Mel Fulks;2701529]So well thought out. I especially like the moulded frame, existing situation is deserving of it. I would prefer a four panel door for better verticality. Think it would be more in keeping with the stone work. But sometimes they won't listen! Old door looks like a most inappropriate replacement .[/QUOT

Thanks very much everyone for the kind words. And a special thanks to Metod for all his help in installing this door as well as the arched French doors I did last Winter. As Metod mentioned, we've become good friends in a short time and owe our meeting in the first place to this forum.

Mel, I really liked the two panel design I was given to work with as the arch follows the arch in the stonework above the door. The old door was original to the 1920's house, but the original panels or more likely lites had been removed sometime along the way and the outside covered with some sort of cheap Masonite type product. On the inside a cheap 1/4" plywood panel had been installed and finished to sort of match the door frame. We were pretty surprised how light the whole thing was when we took it off the hinges. You know how you expect something to weight a lot and when it doesn't it feels really cheap. That was how this door felt. The new one has to be at least 120 lbs. and was the primary reason I didn't install the door panels until after the door was hung. And Metod is right. The new door has a very satisfying "thump" when it closes, the result of being very particular to make sure we got the lockside of the frame perfectly parallel with the door so the door hits the seal perfectly flush as it closes and adjusting the latch strike plate retainer for just the right amount of compression of the seal.

All in all this was a great project. I'm ready to tackle a new front door for my own house next Winter.

John

[Mel Fulks]

John, it's an excellent design and I did notice and admire how it blends in with the top and makes an urn out of the light. It's a long standing prejudice of mine probably caused by clock spandrels !

[Scott T Smith]

Very nice John (as always!)

[Jason Roehl]

I used the ADA compliant threshold and automatic door bottom because it looks better than an adjustable sill and would make it easier to walk over. The concrete threshold is too high and wide to step over as you enter or leave the house and you are pretty much forced to take a step on it to pass through. The low profile of the ADA compliant sill makes that easy to do.

John

That makes perfect sense, and I applaud the foresight--I see too little foresight in new construction projects sometimes. I couldn't, for the life of me, figure out why you would want an ADA-compliant threshold at the top of some steps (not to mention the door knob...).

[Patrick McCarthy]

John, as always, beautiful work and a nice photo commentary. Very much appreciate you sharing this with us, as it inspires me and, I'm sure, many others here as well. Patrick

[John TenEyck]

That makes perfect sense, and I applaud the foresight--I see too little foresight in new construction projects sometimes. I couldn't, for the life of me, figure out why you would want an ADA-compliant threshold at the top of some steps (not to mention the door knob...).


Thanks Jason. I had no clue what an automatic bottom seal was until my pro friend told me about them. The combined cost of the seal and sill is about twice that of an adjustable sill, and it takes a lot more effort to install the seal than other options, but it gives a nice clean look and eliminates the trip hazard of many adjustable sills. I'll probably use the same approach for my own new front door because I have a cement threshold, too.

The lockset/door knob was chosen by the home owner. I take no credit or blame for it. The house is some sort of Spanish style, inside and out, but the owner is an Arts and Crafts fan. Only way I can explain the lockset.

John

[William Fretwell]

I do love a good door! The understated elegance is wonderful, matching the top surround. Hope it weathers well.