Building A Custom Solid Cherry Door

[Music] keep our fingers crossed fingers crossed this client commissioned us to replace her front door using solid figured Cherry we first begin the process by rough Milling the pieces down into their size so that they'll fit on our CNC machine we're using the CNC machine to cut the profiles and joinery that are going to be used to fasten all of these components together what you're seeing us do here right now is putting large bevel on all the components and this is mostly just for Aesthetics just because it helps toine all the edges on our components prior to assembly we also do a light sand on all of the areas that we're not going to be able to reach once everything is glued up specifically the profile can be quite challenging to get in that corner if you don't hit that first and here you can see a good example of the joinery that we're using so it's style and rail joinery we're using typ Bond 3 as an adhesive and then we're using wood dowels to further strengthen this joinery traditionally in order to successfully build a door like this you would have to use mortar and tenin style joinery because the adhesives available at that time were not strong enough to form a joint that was stronger than the wood itself so you would have to figure out some way to mechanically lock those pieces of wood together and that's where the mortise inten came into play modern day adhesives however are much stronger than the wood itself when cured and are going to form a bond that is never going to come apart so that's why we're able to use the styl and rail joinery this piece would was designed as a single door with a single side light and whenever we have a side side light in our doors we do the construction the exact same way that we do the door slab so you see that same style and rail construction the typon 3 the wooden dowels and it will mimic the same joinery and give us the same strength as we have in our [Music] [Music] doors [Music] [Music] [Music] while the door is in the clamps and we're waiting for the glue to cure we can begin working on the frame so something here that you'll notice that's quite different from the door assembly is we're not using any complicated joinery with adhesives here we're using 4in number 12 wood screws to assemble all the components together in our jam and some people may think that you know this is shoddy work or a low quality of construction but we have had no issues in our Jam construction and they're very very strong as a finished product with not much shifting that happens either and you'll see something later in the video that shows how we can account for any shifting that does happen on a big solid unit like this once we've screwed all the components together for the jam itself we can take the sidelight out of the clamps after it's been cured put it into the frame and we can screw that in as well from there we can stand the door up on edge and put our jig on to begin routing out for the hinge gains so here comes the trick that allows us to have adjustability in our door units we purposely machine the gain deeper than it needs to be for the hinge so that we can pack in some shims beneath that hinge and it's not because we accident went too deep it's so that in the case that let's say this door sags we can take a couple shims out of the top suck them back in and then it's going to pull that top Corner in and away from the jam alternatively we can even add shims into the bottom to push it in that same direction so by doing that little step it adds a lot of adjustability into these units once we've got those gains machined we can stand the frame up we can stand the door up and we can do a quick test fit to make sure everything's looking the way we want it before we get this door moved on to the finishing process before we finish we inline sand everything up to 180 grit and then it's upstairs into our finishing area to begin applying the oil finish contrary to what it might look like we're not rubbing coffee into this door to achieve the color uh we're using one of osmo stains I believe this is a custom blend where we've mixed a few different colors together and after we've put the stain on we're going to be applying a couple coats of their UV oil uh We've tested many different exterior oils over the years uh even some for our own formula and we still are testing them we're just not quite there yet but osmo product is tried and true we've used it on many of our doors and had great success with these oilbased finishes in the past we used to use film forming spray finishes which worked initially but you would get a maximum lifespan of about 5 to 10 years especially in environments that had high UV exposure and you would get this eventual flaking and peeling that could only really be fixed by a full stripping and respraying of the door which in some cases with labor could cost like $5,000 with an oil finish when it comes time for maintenance and it's looking a little dry all we do is we go and scuff the door up with a gray pad rub a new coat of oil on come back in a week and add some ceramic and it essentially looks brand new [Music] [Music] [Music] new [Music] once the finishing process is complete we can get the door back down onto the CNC machine to begin routing out for some of the hardware this door did have an electronic lock which is a little bit different than what we typically do usually it's just a full mortise lock set but in the recent past we've seen quite a few more customers requesting these electronic locks to go with their smart home systems once it's off the CNC machine we can pound in some of that Hardware fit that lock onto the front side of the door and then it's time to lift in these panels to get the final fit and and this door ready for install now this is a little bit controversial when we've posted it on Instagram in the past but we're using a two-sided self-adhesive tape to secure these door panels into place and if that concerns you all I can say is that you should probably never fly on a plane because there's a lot of components on an aircraft that are held together with the exact same type of tape we're here with our customer we're going to be replacing their front door uh right now Wendy's still smiling so hopefully she's still smiling at the end of the day and we're looking forward to a great install it's going up to 15° today wish us luck Wy unbelievable weather yeah great I'm very excited about the dwarfs so okay keep our fingers crossed fingers crossed I can hardly wait to see the finished product oh yeah doesn't want to come on on there's just a couple like big nails on this side yeah I can see see good job there probably sideways and down I guess okay and watch yourself cuz it might Spring Loop so why don't you go over there and grab it so I want to go down I P the stre okay no don't let it hit the floor don't let it hit the wood floor let's just go out like this okay that good yeah just take it slow all right but it's okay it's coming loose okay don't she go guys now I don't know if it's stuck on the bottom so kind of pull it out pull stay parallel [Music] and we left because it's likely to scrape on the side and we might have to tuck Curtis's side a little bit come this way you hitting the yeah so we go all the way in so we can do the top first I guess heic yes yeah we can okay let's see what she looks like oh that's lovely that means go to the wall go to the closet farther good on this on the shims okay step one we're really close very good okay got okay it looks pretty close on the top okay okay looks very good that was hard actually to get that to that point there yeah and if you don't do it nobody else does it [Music] so you guys everything grab whatever you want out of the truck this is how thick is that we're going to want to center it so I have to shoot the big n because it's a let me close the door going to put uh ceramic on it right now okay so hopefully you don't have to do too much maintenance but um yeah when you clean it uh you want to use just like if you buy a soap that's like oil friendly specifically that's good uh just don't use Windex Windex and oil are not friends okay well Wendy we were here 6 hours ago this morning first thing about 9:00 it's now 3:00 few things have changed around the front entry your home how do we do Tada it's so beautiful BR I love the color the install was amazing um I mean I can't be happier I'm over the moon with the end product um it's hard when you design something you don't really know what the final product is going to look like but this has turned out beautifully I'm so pleased and very happy thank you for trusting us with all of this Wendy and we have to thank our team we got guys at the back shop that put a lot into this too so again amazing thank you very much you ever need a door adjustment if it ever rubs you just call us we come and do it it's on my way home all right it was worth the wait oh thank you and we got it done on a day we got it done on a perfect [Music] day

Channel: Black Forest Wood Co.

Views: 20,363

Keywords: Resin, Resin Pour, Epoxy, Ecopoxy, Wood, Resin Art, Resin Table, Resin Crafts, Resin River, Epoxy Table, Epoxy Resin Table, Epoxy Resin, Epoxy Resin Projects, Project, Black Forest Wood Company, Black Forest Wood Co, Black Forest, Black Forest Resins, Rich, Money, Expensive, Woodshop, Workshop, live edge, live edge slabs, calgary, canada

Id: RAlX7tA9iQM

Length: 12min 29sec (749 seconds)

Published: Sat Mar 23 2024