Pennsylvania Limestone Farmhouse Renovations to an 1863 farmhouse built of limestone

May 19, 2012

Front Door – Part II

Filed under: Front door — Duane Diefenbach @ 7:35 am

I have the frame for the front door, sidelites, and transom completed except for some final coats of paint (see https://setterrunfarm.com/blog/?m=201204). I started on construction of the door, which I am making from white oak. The wood for the stiles and rail I had to purchase because I didn’t have any clear 8/4 but the panels I am making from the white oak that came down last year on our property.

Here’s what the final product will look like. Above the door is the transom with 6 panes of glass (most of the muntons are decorative interior muntons). Either side is a 3-pane sidelite above a raised panel (same muntons). The original door was simply a 2-panel door and I have chosen to replicate it because a 4-panel door would probably look out of proportion trying to get it to match the raised panels and sidelites.

The lumber has been stickered in my shop for the past month acclimating to stabilize the moisture content. I then started by planing the 8/4 stock and ripping and cutting it to the rough length and width.

The stiles (long vertical pieces) of the door needed grooves cut to hold the panels and mortises to accept the tenons of the rails (top and bottom horizontal pieces).

The base rail is 12′ wide and I made 2 tenons to mate with the stiles. The mortises I first used the drill press to remove most of the wood and then chisels to clean it up. For the tenons I removed most of the wood with a dado blade in the radial arm saw and then used chisels and planes to finish. It takes a good bit of fitting to get them to match (squarely!).

Here’s the door together, but I still need to make the middle stile and fit with mortise and tenon. The door is just under 1-3/4″ thick and once all together I will not be able to move this by myself!

Next post will be about finishing up the door frame and starting on the raised panels.

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