Entry door set

hi everybody I'm Jodi Happy New Year this is the first video of TWiki 19 for me I'm gonna be making this set of doors I've just finished him now by the end of the video we'll be hanging in their place that's tomorrow for me it's pretty comprehensive video it's pretty long one I wanted to be as precise as I could with how this was actually made so I've tried to cut out what I can but it's as long as I think it needs to be so be with me and see you later so I'm using American oak and French oak for this built this thing is just to get you think down to more usable sized pieces this is the quarter sawn French oak for the styles we have the pieces platform American white oak which is what the client really wanted I just couldn't find any Khorasan available with the rails will cut the link I can start forming the Tenon's after laying out the shape of the Timmons I can cut the waste away with the canceled [Laughter] then I can trace the Tenon's onto the sides of the Stiles so I know where to cut the holes and then I made this jig up just for this job where I use a long down cut bit to create the mortise there's the smaller four Qing part of the mortise with that done I can take out the stoppers on the jig and cut the rest of the depth of the large mortise and I can take to the corners of the tenons with the rasp just to make them fit in their rounded corners of their mortise so at this point the styles are too long and the total width of the door is too wide and that's just so I can get it perfectly down to size on a table saw I have to glue up first I've got to make the paneling so I machine up some oak and rip it down so I can make some tongue and groove now can group or the panels on one side and also the doorframe itself and then I can create a tongue on the ends of the panels with the data set and I decided to try and use the data set to cut the long tongues as well which actually worked pretty good [Music] now I can clean up all the inside faces of the rails and styles and then using a little rounding over plane add a small round over to all the edges and it's time to start dry fitting everything all of the panels are in but one and now I clamp up the door as it will be so I can measure what the actual size of the that last panel needs to be not just relying on the theoretical so this last board I had actually planned to have a double ton I ended up with a double groove so not to worry I've just made up a couple of slip tethers floating tails so I'll use these instead then we'll do just the same thing right so that's the first door pretty well fitted up now I need to take all these panels out give them a slight round over sander more and they're going to be pre finished before I do the glue up and I'll probably pre finish the edges of the door as well and then then I'll do the glue up and do a flattening off after that all right so what if we go mortise-and-tenon joints into the door all right hanging on an inch great now of course over time gravity is gonna be pushing down on this side of the door because this side is fixed by the hinge okay what's gonna happen yeah doors gonna wreck even with really good water some tenon joints probably something like that's gonna happen so we're going to put some brace in now in this case my client has decided that she really wants when the two doors are shut together she wants an X brace look and it's a little bit tricky because the it means the bottom brace is gonna be doing all the work and the top brace is going to be doing ya know a heck of a lot I'll show you okay so what we need to do is direct the force of gravity back towards the hinge and the support and wall so what we want to do is add diagonal brace now as gravity has an effect on the door the force comes down style and then this diagonal press forces the the weight back against the style and the hinge and the Stutz the wall so on and so forth so that becomes quite a lot stronger now typically what you do is have another brace on this angle to help support the top of the style the weight coming down to the middle of the door style here of course that's not the shape my client is after so what we're gonna do so this bottom brace is gonna be taking you know the majority of the weight of the door and we're gonna lid this brace in so you'll see what that isn't a second the weight comes down and it's just a squig top joint here it's no special joinery down the bottom here it is some slightly different stuff we're gonna match that joinery on this brace well though see the brace isn't that you're working because as the weight comes down this brace just gets pulled away from style so what I'm going to do is add some Domino's across from the brace to the style here and also from the brace to the style up here and that's hopefully gonna add to supporting the door and it means that the style won't be able to drop down the brace won't be able to drop down and therefore move the outside of this style that's the plan so this is me working out for the alleged join between the brace and the center styles and the reason for this is because all of the weight will be coming down onto that brace you don't want the styled whale to slide along the length of the brace so if there is a positive stop for that brace to be mounted on into the style there will be absolutely no way that that brace is even moving against the style [Music] and yep I'm using that rats a free hand which fights me in the button a little bit as you can see right yeah next where I'm chiseling that I accidentally got the piece I shouldn't get right well it's not the tightest joint you've ever seen what that's tight but this is time to get here but I'll fix it up later you will see how it's not your bit I reckon so my client was after a filly kind of used band or look so the first thing is to apply a dark stain in this case I'm using bright wicks dye stain which is a myths based product and so it dries almost immediately so a nice good thick coat of this stuff and then pretty much sand it all back off again so I sand it back until the point where I see mainly or what I think I see is mainly attend to color and not the stain color and then that's really surprising what happens but clear coat on top of that I'm using a marine grade set an oil-based polyurethane to get ready for the glue up by making a few dowel pins to hold the doll together so just smash a bunch of oak through this piece of steel I've drilled a bunch of holes in all right good luck time wish me luck and I'm using epoxy and this job purely at the time this was a fairly long glue up and even though my joinery it was actually very tight I could have got away with any other kind of glue I really needed the time because it's a pretty long process traditionally these angled braces would just kind of press fit and but I like to add just a dab of glue just so I know it's not going to fall out all right call it cheating I'll call it whatever you like this and I'm just gonna add a little bit of black epoxy to black get oxide see their leftover epoxy there's a couple of gaps in the joinery which I knew we're gonna be there but this is not ideal but this is now I'm gonna get rid of those little gaps because we're staining the oak dot I can kind of get away with a little bit of a dark adjoin line now this actually looks like it really it looks like a terrible join some of it as a shadow from the stain that had come around the edge there is a very small get there and it's also slightly proud which is creating more of a shadow so from your angle it doesn't look too good but I'm just gonna fill what get there is there and I'll sort it out tomorrow with the hand plane so I can add some of your pockets to allow for the hinges I'll talk more about those later so don't start writing comments just yet so with the hinge side straight and hinged up I can trim the other side - it's fine a width and through a nice round over around all the edges give her a nice final stand let's add my makers max somewhere on the door so I thought I would put one of my steel badges in the edge of the door just below the top hinge and I think it worked pretty cool so all the while I've been making this door my client had been trying to find some handles for this thing eventually she found something but the time that she shipped it it it was the new year and here we got in 2019 now finally with the door with okay I feel like I need to explain these hinges a little bit because I know I'm going to get questions about this and the element in frame which you're about to see the reason you've seen the element in frames on the doors I've made on the other videos and this video is to do with the building process here in New Zealand and it's partly to do with the building process and partly to do with the homeowners not being aware of what there's one in the process of getting a quote and doing all the things necessary for the Builder to actually start building the house he provides the homeowner with said quote and that includes full window and joinery price and nine times out of ten that's Elementium joinery here and so it just gets priced in as aluminium joinery into the job the job goes along it progresses the minute the frames stood up the aluminium contractor out he measures up they start manufacturing that process takes a couple of months while the building progresses so when the time comes time for the homeowner to decide what the front door really is actually going to be and they contacted me I say yeah sure I'll come a measure up the space you've got I get there of aluminium frame it's already in because the bill that had to install it so they could carry on doing the cladding on the outside of the building and getting a watertight otherwise this would be coal it holds up everything and it's just not common to have a nice wooden frame to match the door it's sad occasionally I'll catch it early enough where I can tell them but don't get that piece of aluminium made up I'll make a wooden frame it doesn't happen too often so that is why this is dope these doors are going in an element of frame it's not ideal it doesn't necessarily suit it but brain does match all the rest of the house and that means the Builder can carry on with the same details around all the other windows as well we were to say scrap the aluminum frame and pull it out and put a wooden one in we would actually have to make a legal change to the plants and get permission we'd have to pay for the capsule to review those plans and pull that and the other site checks that are necessary for that you could be looking at two to three thousand dollars just for the legal change so it can be get to the point where it's just not worth it where the cost of the frame plus the cost of the inspections and the legal paperwork it just doesn't just just not working out so it's disappointing sometimes but that's that's how it is and the final really crucial thing to add is a weather strip between the doors so I need to route a groove and I can plunge in the rubber strip so now we're on site and a little bit nervous at this point because there's really no tolerance on these doors so yeah but actually as it turned out things went exactly to plan it fitted brilliantly it's really really happy with how the doors fit and everything works just like it should after this was all fitted and installed we ended up taking the doors off and putting them in storage until the house is properly finished thanks for watching everyone

Channel: KingPost TimberWorks

Views: 92,636

Rating: 4.9449329 out of 5

Keywords: making a door, front doors, modern doors, classic front doors, how to make doors, how to, entry door set, door joinery, entry door, braced door, ledged door, staining Oak, dye stain, front door, entracne, entrance doors, how to make braced door, how does door bracing work

Id: Yqf3ZFUrT8U

Length: 23min 29sec (1409 seconds)

Published: Wed Jan 09 2019

Reddit Comments

[u/Not_Joshy]

I love this guy's work. He always makes pretty complex builds look easy, but he does a good job of explaining why and how he uses certain techniques. Plus he always mentions when he makes errors so you can learn from them.

[u/jaayjeee]

Solid work by Joey as usual. If you are interested he has a podcast with RobinLewisMakes and Jordan from Periodic Furniture Studio. It’s called the Shop Stool Podcast and will be returning earl this year I believe. A great option for any other Aussie listeners out there