[Treeoflifestairs.com]

It all started when we moved into our new house and the front door was falling apart. With some work it would shut but it wouldn't latch or lock. This was not acceptable for my wife. We have double doors and the cost to have them replaced with the kind of door that we liked was going to be very expensive.

I drew up a design of what I wanted it to look like then used tape to outline it on the existing door to check the proportions.

 

[Treeoflifestairs.com]

This is a picture of the inspiration behind what I ended up with. We liked the mahogany wood with the glass and iron work. I also liked that parts of it were curved and not just all straight lines.

 

[ThomasOSB]

Looks a good solid design, can't wait to see it come together.

 

[Treeoflifestairs.com]

I found this iron panel but it was unidirectional. They didn't have a mirror image of the same panel so I took it to my welder and had him remove the leaves on one of the panels and weld them back on to face them the other directional that I could place them side by side and when viewed from the outside you would be able to see all the detailing.

After the slight alterations I had them powder coated.

 

[Treeoflifestairs.com]

I got 8/4 mahogany and made an MDF template of the upper curve. Cut out the rails and stiles and laminated the raised panels.

These are pictures of them kind of laid out in position. You can see the tenons well in these pics.

 

[cabinetman]

Looking great so far. That's some beautiful wood you picked out.

.

 

[Treeoflifestairs.com]

In clamps.

 

[Treeoflifestairs.com]

Thanks cabinet man. I was fortunate with it. Most of it had very tight straight grain.

 

[MapleMoose]

That is looking sweet! It is going to be an incredible upgrade!

 

[Treeoflifestairs.com]

First there was one.

Then two.

Testing out the iron and glass panels

The holes and mortising for the hardware is done.

 

[ThomasOSB]

Those look awesome! Are you going to do anything special with the finish?

 

[Kahlua]

I'm interested in how the frame is going to work.

 

[xcanuc]

Wow. Those are absolutely gorgeous.

 

[9poundhammer]

Absolutely gorgeous doors. Great design and choice of materials. Can't wait to see them installed and what choice of hardware you use.

Really great job. Well done

 

[khowald]

Well done is right, the design and execution are amazing... LOVE them, they really POP!!! ken

 

[Ostie]

Awesome craftsmanship! Very well done.

 

[BZawat]

Beautiful doors! Those are going to be sweet for sure

Brian

 

[Fastback]

Very very nicely done. Anyone would be proud to have them hanging in the front of their house. Great work.

 

[Treeoflifestairs.com]

Now it's time to make the jamb.

I had to make a jig for the hinges. The jig I've used in the past (a plastic porter cable one from Home Depot) was either too big or too small.

I chose to bend and laminate the top curved part of the jamb because of the shape of the jamb. There needed to be three 1/4" pieces that were 5-1/4" wide that would be the jamb itself then two 1/4" pieces that were 3-1/4" that would be the doorstop. That would allow for the 1-3/4" door plus 1/4" for weather striping. The doorstop also needed an 1/8" groove in it for the weatherstripping to fit into.

I forgot to take a picture of it all clamped up but this one shows the jacks that I used to bend it.

 

[sanchez]

Those doors are incredible! Thanks for posting.