I saw a very interesting show on DIY network last night (5-2-06) It was on "Restoration realities". They fabricated an authentic design A&C door for a bungalow in Nashville. It looked very nice. This was of particular interest to me since I'm just starting a restoration on a bungalow that also has an ugly metal door. The show will air again, plus you can check it our on thier web site.

i have thought about doing that very thing. a lot cheaper that buying a made door (min $700)

Hi Don,
The web site has a sketch of the door they built as well as pictures. I missed the beginning of the show, so I wasn't sure how they got started. I think I'll be trying this myself. It won't be untill the fall....I should be at the out side stage by then ( I hope!!) Maybe It'll make bungalow of the day!!!....we're a long way from that!! Check it out if you get a chance. Any comments or suggestions would be appreciated.
www.geocities.com/punksquirt03

Doors are not even really difficult to make, they just take a ton of stock. the big problem with doors is that we tend to cut the mortise too tight for the tenon.. When you force a tenon in.. it can cause a door to rack.. That is if you lay the door flat, not all 4 corners will touch. You really need the pocket so the tenon will slide in and out with a little work.. but not have to beat it in with a mallet. You also force a good bit out glue out of the joint while doing so..


I made some 44"x72" doors for a funeral home here in town, red oak 6/4 frame and used red oak plywood for the center panels.. it priced out at $550 .. so doors can be expensive..


You can pick up a nice mortise machine for about $200 (Fisch makes a nice one.. )

Oh.. the other thing is... When you are making the frame, try to get 5/4 or 6/4 stock.. I have seen lots of people face glue 3/4" stock to give them the full 1.5" thickness.. This is asking for trouble.. with the expansion of the wood and the stress put on the frame, it will split.

Also, this is a great application for exterior grade glues (like gorilla glue) that are poly based.


An offer to anyone taking on a woodworking project, feel free to call me if you need any advise or tips.. For the cost of a phone call, it may save you a few headaches..


Rob Bennett

House Of Yesteryear
www.houseofyesteryear.net

(812)236-5493