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.
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.
The window is routed out of the door and more cypress banding is applied to the new opening and on the door face.
The cypress is stained to match the rest of the tiny house trim work.
The inside of the door has the same design, but uses maple and walnut in order to match the planned interior.
Here’s the beautiful door installed with recycled redwood returns.