Building an exterior door
I enjoy woodworking and have done a fair amount over the years as a hobby, but my knowledge is still pretty basic. I'd like advice and opinions on my upcoming project.
I'm planning on building an exterior back door for our Arizona room (along with a wall of windows, but that's the easy part). The door needs to be very strong as it will be around 50 inches wide, and it will have double glazed low E glass instead of wood panels. So I'm thinking for timber of using white oak (reasonable price compared to mahogany) and doing a conventional mortise and tenon frame. with fairly wide boards. 6 inches for the stiles, 10 inches for the bottom rail and 6 inches for the uppers, with full through mortises and using wedges and glue. Double mortises on the bottom rail. No to floating tenons.
This will be the most complex thing I've built in many years, and I want to avoid making mistakes, so please weigh in with any suggestions and tips.
I will have to build a large table to start with, just to have a good flat surface to assemble it on (I don't have a woodworking shop just a small 10x12 shed with a small contractors saw). I'll need to make the tenons using a dado blade to cut the rails as a tenon jig with the boards held vertical is out of the question (40 inch rails on the saw would be too tall for the shed) and I'm trying to figure out how to do mortises this deep... we're talking 6 inch deep mortises! I don't have a mortiser, and was thinking I could build a sled for my router to cut the mortise, but even with the deepest spiral bit I can't see how to make them deeper than maybe 3 inches. I suppose if I was clever AND lucky I might be able to cut the mortise on both sides and meet in the middle?
Any recommendations, folks?
Last edited by tucsonguy1; 08-13-2017 at 11:32 AM.