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Thread: My New Front Door

  1. #1
    Join Date
    Dec 2010
    Location
    WNY
    Posts
    6,540

    My New Front Door

    I saw a door in Germany a couple of years ago that I liked. More importantly, my wife liked it, too, and we both thought one like it would look good on our house.



    With that as the model I designed one to fit the 36 x 80" opening in my house, I'll spare you the build process and just say that I used stave core construction with Sapele veneer outside and maple on the inside. The tempered patterned glass are separate panes that sit against silicone foam and are held by the applied moldings, inside and out. The wood panels are solid, 5/8" thick, again Sapele on the outside and maple on the inside. These photos will give you an idea how it was done.





    My friend came today to help install it. It all went pretty smoothly because we had test fit it before I finished it; highly recommended when not changing the frame.







    John

  2. #2
    Join Date
    Feb 2003
    Location
    Leesville, SC
    Posts
    2,275
    Great looking door.... You did a great job.
    Army Veteran 1968 - 1970
    NRA Lifetime Member
    I Support the Second Amendment of the US Constitution

  3. #3
    Looks fantastic!

  4. #4
    Join Date
    Dec 2016
    Location
    South West Ontario
    Posts
    1,045
    John, you did a fabulous job, a unique look for those parts.
    ​You can do a lot with very little! You can do a little more with a lot!

  5. #5
    Join Date
    Nov 2007
    Location
    Manassas, VA
    Posts
    723
    Very nice door. Where did you order glass with frames for it?
    Ed.

  6. #6
    Join Date
    Mar 2003
    Location
    SE PA - Central Bucks County
    Posts
    52,382
    That really looks outstanding, John!!!
    --

    The most expensive tool is the one you buy "cheaply" and often...

  7. #7
    Join Date
    Dec 2004
    Location
    Cincinnati, OH
    Posts
    699
    Gotta love it. It is beautiful.
    Rustic? Well, no. That was not my intention!

  8. #8
    Join Date
    May 2015
    Location
    NW Indiana
    Posts
    822
    Beautiful door John. Really nice work.
    If you don't stand for something, you'll fall for anything.

  9. #9
    Join Date
    Jan 2004
    Location
    Lewiston, Idaho
    Posts
    27,319
    John, great craftsmanship, unique and certainly it fits with the character of your home. Nicely done Sir!
    Ken

  10. #10
    Join Date
    Dec 2010
    Location
    WNY
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    Quote Originally Posted by Eduard Nemirovsky View Post
    Very nice door. Where did you order glass with frames for it?
    Ed.
    Thanks. The glass is from One Day Glass: https://www.onedayglass.com/ They are individual panes, not sealed glass units. One Day Glass can make sealed glass units, too, but I elected to do it the way I showed. I wrapped the stub tenons that the glass rest on with aluminum tape which does make it look like a sealed glass unit. The glass sits on the silicone foam and then the outside panes get a bead of silicone caulk around the outside edges before the molded frames are set in place.





    One Day Glass is in WA state; I live in NY. It shipped all the way across the country and arrived in perfect condition. Just fantastic packaging. If you look at their website you'll see they have a pretty broad range of capability. I selected a patterned glass, shown under 'Types of Glass - Glass Tints', called "Seedy Reamy".

    John

  11. #11
    Join Date
    Jan 2020
    Location
    West Central Illinois
    Posts
    35
    The door is outstanding! We are not blessed with that type of lumber in the corrupt state of Chicago, I mean Illinois. Can you speak to the workability of the wood?

  12. #12
    Join Date
    Jun 2008
    Location
    So Cal
    Posts
    2,599
    Awesome work John. Very cool design.
    Aj

  13. #13
    Join Date
    Sep 2008
    Location
    N. Idaho
    Posts
    1,023
    Great looking door that compliments your house. And a great memory of your trip

    Best,
    Chris
    "You can observe a lot just by watching."
    --Yogi Berra

  14. #14
    Join Date
    Jan 2009
    Location
    N.E, Ohio
    Posts
    2,831
    Looks fantastic. Great execution as with everything you do.
    George

    Making sawdust regularly, occasionally a project is completed.

  15. #15
    Join Date
    Dec 2010
    Location
    WNY
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    Quote Originally Posted by Christopher Herzog View Post
    The door is outstanding! We are not blessed with that type of lumber in the corrupt state of Chicago, I mean Illinois. Can you speak to the workability of the wood?
    Sapele? I'm sure you can buy it somewhere in Chicago and/or Illinois. Buffalo is a backwater compared to Chicago, so I gotta believe it's available. I buy it from a local millwork company. It's surprising affordable, too, considering it comes all the way from Africa. I pay about $5/BF for nearly any thickness and or width. 8/4 x 16" x 12' is pretty common, and I'm talking QS stuff. Think about the size of the tree that must come from. I mostly buy 8/4 which allows me to slice veneer off both faces and still have 1-1/4" thick stock to use for the stave cores.

    Sapele normally is very well behaved and works pretty easily with both power and hand tools. But every once in awhile I get a board that twists or bows every time you cut it and it's really not much good for anything beyond expensive firewood. Fortunately, once I learned to never buy a board that has any twist, cup, bow, etc in it I haven't had any more real problems. Sapele has a pleasant spice smell; some folks are allergic to the dust but I don't seem to be. Tooling dulls a little faster than with most of the domestic hardwoods I typically use; oak, maple, walnut. Oh yeah, Sapele splinters hurt almost as bad as ones from Ipe'.

    John

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