Front Entry Door

I've been working on this door off and on for a couple of years. There was always something coming along that got in the way.

Well, it's done and in place. Here is the story.

We'll start with the finished door.

This shows the pieces that went into it. Rails, stiles, and loose tenons.

To cut the mortises for the loose tenons I made a guide to use with a router. It fits over the 1 3/4 inch rails and stiles. It was designed to work with a 5/8” OD guide bushing and a ½ inch up spiral router bit.

I needed a guide for the 6" mortises on the 8" center rails, a 4" mortise on the 6" top stile, and a 2" one for the bottom rail. I didn't want to go longer than 6" on the tenons, so the bottom rail has two, and only one is glued.

I made stops so the one guide could be used for all of the mortises.

I also made a spacer for the glue up. It is cut to 1/8" larger than the glass to allow room for the glazing tape.

(BTW, the flattest surface I had for the assembly was my kitchen island)

After gluing the top rail perfectly square to the stile and allowing it to set for a day, I proceeded to use the spacer to attach the rest of the rails with the proper spacing to accept the glass.

Here's a better shot of the spacer.

And more of the joinery.

The door came together nicely.

I don't try to cut the pieces to length. I prefer to build it top to bottom and then cut it square.

I needed to cut trim pieces for the glass. I used the Festool track saw. It was a good way to do it since the off cut piece was under the track and held in place. Much safer.

And a bunch of them.

The track saw setup to cut the trim. I wish I'd gotten more track saw photos. It was a big part of the project.

I used glazing tape around the perimeter of the glass, and on the outer edge.

Here is another interim shot of the assembly.

And that's it. Door done.

Needless to say, I skipped over a lot of details on this write up. If you have any questions, feel free to ask.

Half of what we read or hear about finishing is right. We just don’t know which half! — Bob Flexner

well done,and looks great.

working with my hands is a joy,it gives me a sense of fulfillment,somthing so many seek and so few find.-SAM MALOOF.

Great looking door, it would take a tank to break it down. Great job !!!   Mike
A good-looking door and well-constructed, Nice write up on the process. Well done.

Main Street to the Mountains

There is a very similar project posted on another site (ha ha), I was showing it to my buddy last weekend while we were up at the lake winterizing our boats. He and I built an interior door almost exactly like it for his lake house last year except it was made out of pine. Instead of glass panels we used 1/2" pine plywood (special order). It is a sliding door on barn door tracks. We rabbeted one side of the openings with a router and put trim inside on the other side to sandwich the panels in. One side needed to be flush because it was a sliding door so we made both sides flush. The only other door in the room was an original door from the 1940's and he wanted to match it.  The door weighed 70 lbs. Built the entire door with a track saw and Domino.
That's a pretty solid door.  I don't think it will be coming apart anytime soon.
Great work,  except for the track saw stuff,  should probably delete those pics...  lol j/k of course

Figuring out how to do something you have never done is what makes a good challenge.

Nice write up, thank you!

Ryan/// ~sigh~ I blew up another bowl. Moke told me "I made the inside bigger than the outside".

Thanks everyone!  I was doing the same thing Kenny talked about which was to see how easy it is to take a LJ project or blog and bring it here.  It's just copy and paste.  Couldn't be any easier.

Half of what we read or hear about finishing is right. We just don’t know which half! — Bob Flexner

Nice Door looks great and so well built, good job Rich.

-- Soli Deo gloria! ( To God alone be the Glory)

Thank you very much!

Half of what we read or hear about finishing is right. We just don’t know which half! — Bob Flexner

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