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Custom Panel Entry Doors - Storm Doors

Listing #5078   Listed on: 05/02/2019

Company Name: Hudson Cabinetmaking, Inc.

Contact Name:   Russell Huds
Website:   www.hudsoncabinetmaking.com

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They wanted two, custom panel entry doors with matching storm doors for their country home. He had taken photos of a very old Dutch (2-part) door that had an interesting panel layout. We looked at it together and amended the panel sizes a bit for a single piece door and I began planning.
Their house could see three feet of snow in winter and reach the high 90s in summer, so I needed a species of wood that was strong, would remain stable through the seasons and looked great. I chose an African mahogany known as Sepele. Below you can see the two inch thick, rough sawn planks from the mill and what they looked like after I planed the boards and exposed the faces.


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We had to machine all the parts perfectly square and to the exact sizes so when assembled, all the joints would meet perfectly flush and the doors would be dead flat (‘on plane’). Here we are doing a dry fit (without glue) to see if it will come together as planned.

 
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We ended up creating three hundred and thirty-six pieces of this square molding to hold all the panels in place.

 
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The door’s top half was fitted with tempered glass and the bottom, with wood panels.

 
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Both storm doors and the main doors were mounted with very good hardware.

 
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They wanted brass box door latches and completely hidden scissor hinges that were made in Germany. All of these had to be deeply mortised into all the door’s edges. We had to do the same for the corresponding places on the jambs (door surrounds). We constructed them of thick Sepele and made saddles (the floor pieces), as well. This is referred to as ‘pre-hung’ doors.

 
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Although the painter’s tape is on the glass (they are applying the finish themselves) AND it was snowing outside, I managed to get this photo from the interior. In a few years the patina will look even better. I know they are very happy.

 
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russell hudson / www.hudsoncabinetmaking.com

 
Viewer Comments:


Posted By: Dave Sochar     [05/03/2019]
When I learned Cope and Stick in 1974, it changed my world. So may less parts to make - much less to go wrong in future service.

In this case, you would have made just 32 parts with 44 pcs of stop at the glass. One-tenth the number of parts. I'm trying to be polite, but THREE HUNDRED AND THIRTY SOME PARTS!!!!!????

Square sticking is one of the easiest to set up, even if you don't know cope and stick or have the tooling laying around.

Great design on the doors - very attractive.


Posted By: Russell Hudson     [05/04/2019]
you need a shaper table or a good router table (I have a pretty good one) and then you have to have the right cutter bits, then set up the alignment just right (or remove more material to make the face flush after glue up / if I made my own doors, I would do it but I have little call for that in my shop. Making my own doors for cabinetry is just not cost effective considering what you can buy them (good ones) for. Same reason I don't own a lathe and I have only so much room in the shop / with my router table, I have trouble getting a consistent height position for the cutters / I would have to have done that more often in the past to decide to use it here / if I'd had a shaper table & the bits needed, I might have gone that way / would have been easier that way and stronger, I suspect / the router table needs a long bed (before & after the cutter) and a dead true (steel) bed / just wasn't comfortable trying that here



Posted By: Tom Gardiner     [05/05/2019]
You had better tool up! You are going to get a lot of requests for doors after your client's friends see these. What's the point of being in woodworking if not to buy more tools?


Posted By: Russell Hudson     [05/05/2019]
hahaha / tru 'nuff, Tom


Posted By: Alexander Hendrick     [05/10/2019]
Nice door Russell. What is the joinery method used ?


Posted By: Alexander Hendrick     [08/12/2019]
Seriously curious, motise and tenon? Slip tenons? Domino ?

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