This video demonstrates the process of building a solid wood exterior door for your house. It is the first part of two videos, covering the creation of a beautiful panel door. The video explains the importance of careful planning and precise planning when building a solid wood door. The necessary tools and materials include wood boards, measuring tape, saw, planer, chisel, drill and drill bits, and wood glue.
To create a durable and impressive solid wood exterior door, one must measure and cut the wood to the desired size, assemble the pieces with screws and glue, and sand the surface before applying paint or stain for a finished look. Natural builder Ben Graham and custom woodworker Mike Lamp demonstrate how they recently designed and built a 3-1/2-in.-thick R-10 wood door using salvaged cherry lumber. Panels can be veneered plywood or hardwood, and there are other ways to build doors, including using solid timber or plywood in lieu of quarter-inch doors.
The inner frame is made by running 5/4 decking lumber through a table saw to make it exactly 5 inches wide. The door’s components include the frame, hinge and lock stiles, and mid stiles. The beam is cut to a rough length to make it manageable to handle. The door size is 76 inches by 28 inches, and the video covers the basic approach to building insulated, exterior doors and key details for making success happen.
📹 How to Build a Solid Wood Door / Start to Finish / Fine Woodworking
My friends over at Greene Street Joinery our building solid pine doors for a client out in the Hamptons. In this step by step video …
Can a solid wood door be used for exterior?
Interior doors should not be used as exterior doors due to their inability to withstand harsh weather conditions, which can lead to wear and breakage, potentially causing water damage. Additionally, interior doors do not offer adequate security, as they are designed for privacy and noise reduction, and do not offer the same level of protection against intruders as exterior doors. This can result in the risk of theft, burglary, or violence for the occupants of the building. Therefore, they should be replaced promptly to prevent potential damage.
How strong is a solid wood door?
Solid wood doors are a popular choice for homes and front doors due to their strength and resistance to break-in attempts. With an average weight of around 150 pounds, these doors are difficult to dent and require more force to open than a kick or shove. To maintain their strength, doors may need to be impact-rated DP-50 or DP-70, which are subjected to extreme testing conditions to simulate hurricane-force winds. Wood doors are also durable and repairable, unlike aluminum and fiberglass doors which are often considered inexpensive.
Metal and veneered doors are difficult to repair and often require replacement, while solid wood doors can be sanded and refinished multiple times. Overall, solid wood doors offer a reliable and secure option for home security.
What’s the difference between a solid core door and a solid wood door?
A door flush is a door constructed of a flat solid core. It is a sturdy and heavy door, and is commonly used due to its solid nature, although it is not a door constructed of solid wood.
How do you weatherproof a wooden exterior door?
To waterproof a wooden door, use varnish or lacquer for a long-lasting, waterproof, and weatherproof finish. While it may not provide the same visual appeal as oil or paint, it provides the strongest protection. Regular maintenance and refinishing are crucial for long-term protection against rain and damp. Inspect the door regularly to see if moisture is still beading on the surface, and if it starts to absorb, refinish with another layer of paint, varnish, or oil.
Is solid wood good for outdoor?
Natural wood is a versatile material that adds warmth, texture, and beauty to exteriors and gardens. It is suitable for outdoor use in garden furniture, flower beds, trellises, fenceposts, house siding, and decking. However, hardwoods are subjected to insects, moisture, fungi, and direct sunlight, requiring chemical treatment to prevent decay. To ensure durability, it is essential to select hardwoods with superior decay resistance, especially with ground contact. Factors to consider when selecting hardwoods for outdoor projects include their type, application, and the needs of the DIY woodworker, furniture manufacturer, or building contractor.
Are solid wood doors heavy?
Solid wood doors are expensive and require more maintenance due to their natural nature. They are also heavy and may require alterations and adjustment during fitting, adding to the overall cost. Hollow core doors, made from a thin layer of wood or fiberboard, cover a honeycombed interior core of cardboard or plastic. These doors are generally cheaper than other options and are often found in new homes not at the luxury end of the market.
However, hollow doors are never truly hollow and always have a honeycombed interior. They are only suitable for internal use and have low durability, insulation, and offer minimal soundproofing. Hollow doors are not truly hollow and are only suitable for internal use.
How much solid wood is on the sides of a hollow core door?
Hollow core doors have a strong block outer frame, leaving a couple of inches of solid wood at the top, bottom, and sides, making them more forgiving than initially thought. However, cutting off too much of the door’s top, bottom, or sides could damage its structural integrity. Trimming off an inch or so is acceptable for thicker carpet, misread tape measure, or wonky doorframe, but it is important to avoid damaging the door’s structural integrity.
What material is strongest for front door?
Steel doors are the most durable and effective defense against unwanted visitors, with exterior steel doors being the most durable. Fiberglass doors are slightly less durable but require less maintenance due to their rust resistance. Steel doors are popular for commercial buildings and residential homes due to their style and security. They come in various paint or stain finishes and are typically smooth, with some wood grain textures available.
Steel reinforced doors are the strongest on the market, but some maintenance is required to prevent rust from forming and weak spots. Steel doors offer several benefits, including increased security, style, and durability.
What is the most efficient exterior door material?
Fiberglass is the most energy-efficient front door material due to its durability and ability to resist heat transfer. Its heat-resistant properties make it ideal for homes with exterior heat. Fiberglass doors are also customizable, with options for smooth, modern, or other styles depending on the home’s style and architecture. Unlike aluminum and wood, fiberglass does not conduct heat well, making it a good choice for Triad homeowners. Additionally, adding energy-efficient glass windows to your front door can further enhance its energy efficiency.
How are solid wood doors made?
Solid wood doors are crafted from wood that has been selected for its durability and longevity through a process of drying and other techniques. Such doors can be customized with carvings and design alterations, thereby creating a unique and bespoke product. Solid wood doors are durable, making them an optimal choice for high-traffic areas due to their strength and resistance to wear and tear.
What is the best wood to make an exterior door?
Four popular wood choices for a front door are Douglas Fir, Knotty Alder, Sapele Mahogany, and White Oak. These woods offer charm, strength, and exceptional stain or paint possibilities, ranging from classic to modern to rustic. Each wood type has its own distinctive texture, warmth, and personality, with varying grain patterns and rich colors. The first step in selecting a door is to examine the unique aesthetic and performance qualities of different wood species.
It’s also essential to consider the door’s compatibility with your home’s interior elements, such as flooring, cabinetry, trim, and millwork. Matching your exterior door to your interior style maintains a cohesive design flow, making a great first impression on guests and boosting your home’s curb appeal. By considering these wood choices, you can create a resilient, personalized entrance for your home, enhancing both the exterior and interior aesthetics.
📹 How to make a solid wood exterior door for your house
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My friends over at Greene Street Joinery our building solid pine doors for a client out in the Hamptons. In this step by step article Jeff and Rob will show us how they build one of the doors. You can see how these doors will look in a few weeks when they’re installed by following Greene Street Joinery on Instagram at this link. instagram.com/greene_st_joinery/ Thanks for perusal, Jon
Great article Jon, Jeff and Rob, and perfect timing too! I just got a lead with a contractor looking for some custom barn style doors for an 1850’s house he’s redoing for his wife. I’ve done panel cabinet doors but nothing as large as a full size door. I’ll definitely be applying what I just watched to my knowledge base. Thanks!
Just so happens I have an almost identical door project sitting in limbo in my garage, awaiting answers and some inspiration. Our son’s condo has an exterior wooden door to an attached storage unit that some bozo replaced with an interior, skinned particle board door, which, big surprise, has totally disintegrated. And I happen to have an entire dismantled wooden patio cover in my side yard, a pile of pine and fir 4 X 10s and 6 X 6’s. Full of knots and nail holes, but with enough selective cutting, I’ve made up most of the rails and stile blanks I need. Have been debating plywood or solid panels, but these solid panels look fantastic. That door they made is nearly perfect size wise. Thanks for all the help!
Totally enjoyed the article 😊. I’m a carpenter & joiner with 40 years experience, not used my df700 yet and watched a few articles on solid door construction, pleased I waited for your because the lack of haunches on tenons bothered me, the stud tenons on the rails is simple ( probably) and clears my issue up completely 😊😊😊. I’m hoping the panel buddies are listed on here because I’m in Australia and mass produced door is the norm here which after 13 years living still doesn’t impress me lol, in the main if you buy a solid door here it’s mainly veneered normally 1-1.5mm over finger jointed timber (ISO minded) which once again is not what I expected. So once again totally impressed with the article and of course your joinery and ethics of building the best quality doors I’ve seen using domino df700 Many thanks and regards Trevor
When your getting the lengths of your rails, switch boards around from the way you had them, outside edge to outside edge with the groove facing out..then measure the remaining materiel between the grooves like you did..put the tape on the finished dimension and what’s left is the exact cut length..no need to ad anything
I needed a door from my driveway to my patio wide enough for an offset smoker, with attached tray. So, since 38″ w doors aren’t available, I made my own out of rough cedar that I milled down to 1 3/4″. I also used the 12mm x 240mm dominoes for the joinery. The 1st door I made like this, I used 1″ mortise and tenon joinery, but it did not hold up after some tree guys were carelessly bringing a cut tree through the opening. It’s been 3 years since I hung the new door and still looks new. I did a few things different, but the end result is the same. Thanks Jon for this trip to a custom shop showing their methods, and methodology. Nice work Greene Street Joinery, hope to see more.
I’d like to know why all the machinery is needed to make doors in this century when the doors they made for building and churches is Europe hundreds of years ago are still in use and looking beautiful. I’m into architectural history in design as a little hobby. I don’t build (although I would love to) I’ve only built a table. I just wonder if in today’s world we are over complicating things? I have a door design in my imagination that I would love to bring to fruition but looking at what all you all are doing in this article I’m thinking it’s not possible unless I find a more historical approach to making doors.