Lynn Kasdorf
07-10-2006, 1:00 PM
As my Barn-Taj-Mahal workshop extravaganza project proceeds along, I am at the point where I need to make a decision of how I am going to make my extrerior doors.
On the low side of the bank barn, I have 4 bays that need double swinging doors (thats a total of 8 doors). No, I cannot use sliding barn doors because of a variety of factors. The openings vary from 11' wide to 8' wide, and are about 7 1/2' tall. The doors will open out.
It is an 1849 bank barn, and I have just finished completely re-siding with white oak 1x12's and painting barn-red. I plan to keep the old-barn look with my doors as much as possible, but I want them to seal and insulate reasonably well, and not warp crazily as they age. Also, they need to be rot-resistant.
The weight should be as light as possible, but they cannot be flimsy. If the wind catches the door, I want it to hold up. I plan to fashion massive strap hinges from 2" x 3/8" steel.
Piece of cake, eh?
Here are some basic approaches / ideas I am kicking around.
1. Make doors from 1x6 T&G white pine, or PT pine, or cedar. On outside, fashion border and X bracing from 1x6. This is a simple old-fashioned approach that probably will be fine. I wonder about dimensional stability and rot.
2. Make doors from white oak 1" stock. The problem here is that I need to use dried stock, and much of what is left is split and cupped, even tho I stacked and stickered it, and anchorsealed the ends. Also, oak doors will be heeeeaaavvvvy. Very authentic, tho.
2. Make sandwich of 7/16" T-111 (pt if I can get it), foam/foil insulation board, 1/2" ply (inside). These will be contained in frame made of pt pine or white oak. Or some other variation whereby plywood is the structural heart of the door. Maybe 1/2" PT with frame and T&G planks on the outside. (one problem is some of the doors are wider than 4').
3. Make frame from oak 1x6, M&T or lap joints (the stock I have is about 1 1/8" thick rough sawn). Skin with metal siding panels.
3. Involve vinyl planks (that stuff at Home Depot in the trim department) for the frame, maybe only along the bottom.
Whatever I do, all end grain will get sprayed with copper green rot preventative, primed and painted.
This is one of those tasks I have been putting off because I didn't have a clear way in mind to do it right. Any ideas would be welcomed.
On the low side of the bank barn, I have 4 bays that need double swinging doors (thats a total of 8 doors). No, I cannot use sliding barn doors because of a variety of factors. The openings vary from 11' wide to 8' wide, and are about 7 1/2' tall. The doors will open out.
It is an 1849 bank barn, and I have just finished completely re-siding with white oak 1x12's and painting barn-red. I plan to keep the old-barn look with my doors as much as possible, but I want them to seal and insulate reasonably well, and not warp crazily as they age. Also, they need to be rot-resistant.
The weight should be as light as possible, but they cannot be flimsy. If the wind catches the door, I want it to hold up. I plan to fashion massive strap hinges from 2" x 3/8" steel.
Piece of cake, eh?
Here are some basic approaches / ideas I am kicking around.
1. Make doors from 1x6 T&G white pine, or PT pine, or cedar. On outside, fashion border and X bracing from 1x6. This is a simple old-fashioned approach that probably will be fine. I wonder about dimensional stability and rot.
2. Make doors from white oak 1" stock. The problem here is that I need to use dried stock, and much of what is left is split and cupped, even tho I stacked and stickered it, and anchorsealed the ends. Also, oak doors will be heeeeaaavvvvy. Very authentic, tho.
2. Make sandwich of 7/16" T-111 (pt if I can get it), foam/foil insulation board, 1/2" ply (inside). These will be contained in frame made of pt pine or white oak. Or some other variation whereby plywood is the structural heart of the door. Maybe 1/2" PT with frame and T&G planks on the outside. (one problem is some of the doors are wider than 4').
3. Make frame from oak 1x6, M&T or lap joints (the stock I have is about 1 1/8" thick rough sawn). Skin with metal siding panels.
3. Involve vinyl planks (that stuff at Home Depot in the trim department) for the frame, maybe only along the bottom.
Whatever I do, all end grain will get sprayed with copper green rot preventative, primed and painted.
This is one of those tasks I have been putting off because I didn't have a clear way in mind to do it right. Any ideas would be welcomed.