Pennsylvania Limestone Farmhouse Renovations to an 1863 farmhouse built of limestone

June 28, 2012

Front Door and Powder Room

Filed under: Front door,Interior — Duane Diefenbach @ 7:57 pm

Work on the door has not progressed very much partly because the lockset I ordered has been back-ordered for 2 months. I finally cancelled the order. I wanted to install a federal-style mortise lockset, which would have a simple brass knob and keyhole (oftentimes silvered) but I couldn’t find an antique one for a left-hand door.

I think we’re going to instead buy an antique Victorian style entry lockset that was made in the 1870s to 1880s. However, I need to install the lockset before I can install the bronze interlocking weather stripping. The weatherstripping will go around the sides and top of the door. On the bottom I will install EPDM (rubber) roofing material to act as a door sweep on the bottom of the door.  To do that I had to rout a dado in the bottom of the door.

The photo below shows the multiple mistakes I made with the router and had to patch in pieces with epoxy and try again. I am now pretty good at fixing these types of mistakes.

Below is a photo of the door showing the jig I had to make to support the router when cutting the dado in the bottom of the door. Also, there is a close-up of the joints and dowels holding the tenons in place. I used epoxy to glue everything together. This door is going to be REALLY heavy (like 150 lbs!).

So, once this door has a lock installed then I can get the door frame (which will include the transom, sidelites, and panels) installed in the house. Right now this is what the door frame looks like.

In the meantime, I am working on the vanity for the powder room just off the mudroom. This room has had a function toilet for a number of months but no sink.  The solution is on its way.  The design will be a cherry cabinet that supports an undermount sink on a slate top.  Here’s the cabinet:

The vanity top was constructed by first using 5/8″ plywood base with the oval cut out to allow the sink to fit. Then I fit cherry trim that will serve as edging and enclose the slate top. I glued the slate to the plywood using construction adhesive and marine epoxy to fill the gap between the slate and the cherry edging. I used a carbide-bit in a jigsaw to cut the oval for the sink and carbide-tipped hole saws to cut the openings for the faucet. Regular hole saws finished the cuts through the plywood.

Here’s a photo of the slate installed and epoxy hardening:

After the epoxy hardened overnight I then sanded everything smooth and used a 3/8″ roundover bit to round the cherry edging. I am now working on finishing the cabinet and top. Here’s the top ready for a finish on the cherry (the slate just gets mineral oil):

The next post should have the finished vanity and the installation – except I still need to make the door for the cabinet. It should be pretty easy except for accomodating the baseboard trim (not much space to work in the powder room).

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