Front Door Masterpiece

My Dad and I had many discussions over how to construct a front door that would last a minimum of 50 years. He’s the professional wood worker and I’m the designer. I’d rattle off suggestions and we’d mull each of them over. Usually there was a flaw in the idea that would lead to a shorter lifespan on the door. However, one day I mentioned using a solid plywood core with cedar and cypress laminated to the exterior. We must have thought about that approach for months before the time came to give it a shot.

We worked out a few more details and epoxied two 1/2″ thick sheets of marine grade plywood together for the core. Then we added 3/4″ thick cypress banding to all the edges with more marine grade epoxy. This step capped off the plywood core with a more whether resistant wood.

Plywood core capped with cypress

Plywood core capped with cypress

Sanded the door faces flat and added the cypress to the exterior face of the door. Then added lots of weight on top and let it cure overnight.

Under about 600 lbs. of weight while curing

Under about 600 lbs. of weight while curing

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A good start to the outside face of the door.

The window is routed out of the door and more cypress banding is applied to the new opening and on the door face.

Window is cut out of the door

Window is cut out of the door

The cypress is stained to match the rest of the tiny house trim work.

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Staining the cypress on the face of the door

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Cedar panels are added to the outside face

Stainless steel piano hinge

Stainless steel piano hinge

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Scout hanging out in the wood shavings again

Outside face of door finished and sealed

Outside face of door finished and sealed

The inside of the door has the same design, but uses maple and walnut in order to match the planned interior.

Interior face of door

Interior face of door

Final shaping for a perfect fit

Final shaping for a perfect fit

Kayle keeping watch on the porch

Kayle keeping watch on the porch

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Drilling for the door hardware

Knob and deadbobolt installed

Knob and deadbolt installed in the door

Chiseling out for the strike plates

Chiseling out for the strike plates in the door frame

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Strike plates installed

Here’s the beautiful door installed with recycled redwood returns.

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Now that’s a good looking custom door

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Categories: Tiny Home: Arborion | Tags: , , , , , , , | 2 Comments

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2 thoughts on “Front Door Masterpiece

  1. Your custom made door is just beautiful! Your entire Tiny House is a work of art.

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