Building passage doors (batch 4)....

[mreza Salav]

eryone,

Some of you may remember we built our house 8-9 years ago and I did a lot of work myself (documented here) including building 31 interior doors out of Maple. The following 3 threads from 2013-14 are for those builds:

https://sawmillcreek.org//showthread.php?205854-Building-a-few-interior-doors&highlight=
https://sawmillcreek.org//showthread.php?210969-Second-batch-of-doors&highlight=
https://sawmillcreek.org/showthread.php?214011-3rd-(and-Final)-batch-of-interior-doors&highlight=

I have decided to finish our basement and am doing most of the work again myself. Will add some photos to the original thread of house build but for now I am doing another batch of passage doors for basement: 12 doors this time. I am lucky to have Festool Domino 700 this time which makes the joinery a lot easier. Here are some photos.
First the pile of 8/4 Maple and some sheet goods for panels and other stuff to be built later.

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Then dressing them and getting the pieces ready:

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Then dressing them and getting the pieces ready:

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My body doesn't have the same strength as before, so am using the power feeder to push through the boards for making the 3/4" wide dado for the panels.
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[mreza Salav]

Today I managed to glue up 4 doors yesterday and today. After the glue up will have to mill trims and then make the various holes for hinges and lockset and then make the jambs.

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[Frederick Skelly]

That's a nice shop Sir! Look forward to seeing more of this build.

What are you using for the panels in the doors?

[joe maday]

Today I managed to glue up 4 doors yesterday and today. After the glue up will have to mill trims and then make the various holes for hinges and lockset and then make the jambs.

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ambitious project. They look like they will sound nice when opened/closed...not light like todays doors.....nice clean work! Happy Holiday

[Dan Friedrichs]

Very impressive! I second Joe's comment that I bet these "feel" pretty great to close.

[Jim Becker]

Really nice that you can continue your fine work for the additional space!! And yes, the Domino 700 is a wonderful tool for this...the 14mm tenons are pretty stout.

[mreza Salav]

Thanks everyone. The doors are 1 3/4" thick with 3/4" sheet panels. They do make a satisfying sound when closing and work well in sound proofing too. The only downside is they are heavy and can snap a few fingers if they get caught!

[Patrick McCarthy]

Mreza, i remember the build thread very well, but am surprised it was 8-9 years ago . . . i would have thought maybe 3-4 at the most. Looking forward to this one too. Best, Patrick

[mreza Salav]

Mreza, i remember the build thread very well, but am surprised it was 8-9 years ago . . . i would have thought maybe 3-4 at the most. Looking forward to this one too. Best, Patrick

Thanks. Yeah time flies, doesn't it? I started the first batch of doors in 2013....

[mreza Salav]

Here is an update. I wasn't able to work on these for a few weeks but back at them. Doors are all glued up. Then made a whole bunch of trim moulding for them and more. Extras will be used elsewhere for some panels on the walls.

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i have sanded 10 out of 12 doors and installed the trims. Jambs are also built and ready. Hopefully will start hanging them next week.

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[Jim Becker]

Those are beautiful doors, mreza!!!

[brent stanley]

Looking great Mo, nice to see you back around!

B

[Nick Lazz]

Do you have a standard width you use for stile and rails? I have limited door building experience and kind of just went with what I thought looked good and would support the hardware.
Also, for interior doors, was 1-3/4 just what you prefer vs 1-3/8? I suppose a 1/2” dado and panel for 1-3/8 doors?

Really like following your progress. Doors look great!

[mreza Salav]

Do you have a standard width you use for stile and rails? I have limited door building experience and kind of just went with what I thought looked good and would support the hardware.
Also, for interior doors, was 1-3/4 just what you prefer vs 1-3/8? I suppose a 1/2” dado and panel for 1-3/8 doors?

Really like following your progress. Doors look great!

Thanks Nick. The width I have for rails/stiles is something I came at myself. The stiles and top rail are 5.25", middle rail is 6.5", and the bottom rail is 8.25".
With these numbers the 36" (from the bottom) for door handle will be right at the middle of the middle rail, also the 2 3/4" spacing from the edge for the handle is (almost) middle of the stile as well. And the aspect ratios seemed good to me.
I start from 8/4 material and by the time joining/planing is done I'm slightly under 1 3/4" (between 1 5/8" or 1 11/16"). I have 3/4" dado for panels, so about 1/2" (or 7/16") for the trim moulding.

[mreza Salav]

Doors are all done and hung, trims installed. These photos are from last night (I have not finished installing door stops which are not shown in the photos).

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[Mel Fulks]

Looks good ! Give us an update, is that the same house ? Or the second one?

[mreza Salav]

Thanks Mel. Same house, finishing the basement.

[Chris Fairbanks]

Today I managed to glue up 4 doors yesterday and today. After the glue up will have to mill trims and then make the various holes for hinges and lockset and then make the jambs.

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Very nice. I am contemplating building doors myself as I start on remodeling our 20+ year old house. The doors the builder used are not complete crap but only a step or so above. I have a question though as I have never built normal doors before. Is that small tenon on the rails along with the dominos enough to handle heavy day to day abuse by kids shortly becoming teenagers? My original thought was I was going to have to build long tenons to do something like this and that would be a lot of work vs what you are doing here. Of course it means I would need to buy the larger domino to compliment my smaller one :)

[Jim Becker]

They look outstanding, Mreza!!

[mreza Salav]

Very nice. I am contemplating building doors myself as I start on remodeling our 20+ year old house. The doors the builder used are not complete crap but only a step or so above. I have a question though as I have never built normal doors before. Is that small tenon on the rails along with the dominos enough to handle heavy day to day abuse by kids shortly becoming teenagers? My original thought was I was going to have to build long tenons to do something like this and that would be a lot of work vs what you are doing here. Of course it means I would need to buy the larger domino to compliment my smaller one :)

Thanks Chris. The previous 31 doors I made (for the rest of the house) I used 1/2" dowels (didn't have domino at the time). I had 15 dowels on each side of the door (30 per doors). With panels being glued that's way more than strong enough. The home made dominos I am using are strong enough to hold the door together with the glued panels. I really don't need those little tenons at the end of the rails it's just easier to have them because the stiles have a 3/4" groove to receive the panels. So better/easier to have those small tenons at the end of the rails as well.

[Nick Lazz]

Awesome job 👍🏽

[Mitch schiffer]

Looks nice. How do you like the power feeder on your jointer? I was thinking about this but I thought it would be a lot of adjustment since the board is thinner every pass.