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new life for an old bird

9K views 46 replies 34 participants last post by  Dennisgrosen 
#1 ·
eagle inlayed door re-use

this is a door i made 20 years ago , for my then new home .
i worked in a production cab. shop at the time ,
and built it after work in that shop ,
every morning one of the owner's would say ,
" that's a nice door , but get it out of here ,
we need the room " . not really true , as it was stashed away in a corner of the shop .
so i was under pressure to finish it !
it is 3' 6" x 6' 8" x 1 3/4" ( 42" x 80" x 1 3/4" ) exterior entry door .
the frame is pine morticed and tenon with a 3/4" ply insert ,
and the inlay was done in 5/4" redwood and pine ,
then re-sawed inlaid in door and glued to both sides .
notice the eagle looking in different directions .
it was exposed to the weather ( rain , snow , and very hot new mexico sun ,
for 5 years , before we could build a porch and roof over it ,
thereby protecting it somewhat . after an amicable divorce ,
my ex wife started renting the house , and the ensuing renters
somehow proceeded to slowly destroy the front door .
10 years of this abuse , with me fixing it as i could ,
finally led to a new door and casing , that we (ex wife and i ) ,
made and installed . so i got this back , it's pretty beat up , and the inlay is gapping somewhat .
i plan on patching it up and filling the gaps with epoxy , and after another sanding ,
sealing it in epoxy and making a stand for it that i can have the door rest in ,
and turn it over once a year to reveal both sides to the sun ,
it will make a great table for my 20' x 50' deck !
watch for future progress !
thanks .

 
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#7 ·
thanks guys ,
here is some detailing ,
i still have the full size pattern i made from poster board ,
draw it out full size , mark the color and put an arrow on each part ,
in the direction of the grain you want , cut with a razor knife ,
mark the parts and cut ,then fit them and glue ,
2 by 2 and then sections together , re-saw .
you still have a pattern if a part gets blown !
 
#13 ·
Wow! That is some door! I have always loved hand-made front doors. I designed mine and had it built in CA… you can imagine the shipping on that one!
David, you are an incredible craftsman. You design, create and, most importantly, share willingly.
Ellen
 
#17 ·
david, that is a very comforting post. if you could do things like this 20 years ago, maybe i can do the things you do now in 25 years from now! (that is, if arthritis will not get me first)
 
#24 ·
table base ready

well i've been busy
making the base for my old door
for the back deck
and here it is
Rectangle Wood Outdoor furniture Slope Wood stain

.
and here are some details of the build
this is the corner connection
had to use carriage bolts
'cause that's what i have
so i glued and screwed blocks to the rails
and bolted thru them
this re-enforces the corner
and the leg
(notice the drain holes against the rail for rain)
Wood Rectangle Wood stain Plank Hardwood

.
here is the cross bars
for when i flip the door over
(it's the same on both sides
the eagle just looks the other way)
i did a boat taper connection
by angling the ends into angled notches
so the weight of the door flipping
won't break the lap or screwed butt joint
Brown Wood Plank Wood stain Tree

.
here is the frame done
except for spar varnish
and some plugs
it is solid!
Wood Rectangle Flooring Floor Wood stain

.
and here it is with the door in place
the door needs epoxy and sanding
and spar varnish for the UV rays
after 'dutchmen' (plugs)
are in place to keep it from rotting
in the rain and sun
Table Wood Rectangle Desk Plant

.
Plant Table Outdoor table Wood Outdoor bench

.
so there you have it for now
will probably do the door itself inside this winter

next is buddy's door
(he get's impatient with me
when he want's to get in and out)
the eagle door was in the way
where i want to put his

but tomorrow moving the 850lb 20" planer on to the deck
where i have a 220v plug ready for it

thanks for looking
have a great holidays !
 

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#25 ·
table base ready

well i've been busy
making the base for my old door
for the back deck
and here it is
Rectangle Wood Outdoor furniture Slope Wood stain

.
and here are some details of the build
this is the corner connection
had to use carriage bolts
'cause that's what i have
so i glued and screwed blocks to the rails
and bolted thru them
this re-enforces the corner
and the leg
(notice the drain holes against the rail for rain)
Wood Rectangle Wood stain Plank Hardwood

.
here is the cross bars
for when i flip the door over
(it's the same on both sides
the eagle just looks the other way)
i did a boat taper connection
by angling the ends into angled notches
so the weight of the door flipping
won't break the lap or screwed butt joint
Brown Wood Plank Wood stain Tree

.
here is the frame done
except for spar varnish
and some plugs
it is solid!
Wood Rectangle Flooring Floor Wood stain

.
and here it is with the door in place
the door needs epoxy and sanding
and spar varnish for the UV rays
after 'dutchmen' (plugs)
are in place to keep it from rotting
in the rain and sun
Table Wood Rectangle Desk Plant

.
Plant Table Outdoor table Wood Outdoor bench

.
so there you have it for now
will probably do the door itself inside this winter

next is buddy's door
(he get's impatient with me
when he want's to get in and out)
the eagle door was in the way
where i want to put his

but tomorrow moving the 850lb 20" planer on to the deck
where i have a 220v plug ready for it

thanks for looking
have a great holidays !
Beautiful!
 

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