Popular Post bradpotts Posted May 20, 2017 Popular Post Report Share Posted May 20, 2017 I started a door a little bit ago. Sorry it isn't more step by step. I want to share but also have deadlines. I started by making the styles and rails. I made them stave core style. They are the same as the last doors I posted about. Here is what that looked like. I decided to take the easy domino route because I already made 14 interior doors and didn't feel like making them traditionally. After that I started making the panel for the bottom. got everything glued up and almost punched myself in the face. Wasn't thinking about it being an exterior door and used titebond original. The thickness was about 1/16 larger than it needed to be. I had a long talk to myself about doing things not because they were easy but because they were right. I then ripped the panel back down to strips. This time I had to use dominos because I couldn't lose any thickness. Just cost me a couple hours of work but better than years of wondering if the glue failed. After that I started making the grooves in the panel. I decided to cut the groves after the glue up. It doesn't matter which way you do it I just wanted more control over the depth of the groves so I cut them after the panel was glued up. First I needed to come up with a jig to cut the groves so I made one using my track saw. worked beautifully. I cut the dados in the rails and the rabbits to fit in them. They were stoped dados. I made my second mistake by putting the domino to close to the dado. Not worried about it though. cut it close then cleaned everything up with planes. #hybridwoodworking ! Did a test fit. everything looks good. On to the next part. I am making stained glass for the top. I have never done this before but excited to try something new. Here is the design. to be continued! 5 Quote Link to comment Share on other sites More sharing options...
Dknapp34 Posted May 20, 2017 Report Share Posted May 20, 2017 Looks great...except for that can of Coors Light. Work like that deserves a good beer! Sent from my iPad using Tapatalk Pro 1 Quote Link to comment Share on other sites More sharing options...
Popular Post bradpotts Posted May 20, 2017 Author Popular Post Report Share Posted May 20, 2017 Looks great...except for that can of Coors Light. Work like that deserves a good beer! Sent from my iPad using Tapatalk Pro Ha ha I can't afford anything better. 3 Quote Link to comment Share on other sites More sharing options...
davewyo Posted May 20, 2017 Report Share Posted May 20, 2017 Looks like nice clean work, Brad. That's an attractive door. Do you have your own one person business, or are you part of a bigger production shop? I'm really looking forward to what you do with the stained glass. If you can, give us lots of detail on your technique. Quote Link to comment Share on other sites More sharing options...
Eric. Posted May 20, 2017 Report Share Posted May 20, 2017 Looks good man. I've always wanted to learn stained glass. Glass is cool. 1 Quote Link to comment Share on other sites More sharing options...
bradpotts Posted May 20, 2017 Author Report Share Posted May 20, 2017 Looks like nice clean work, Brad. That's an attractive door. Do you have your own one person business, or are you part of a bigger production shop? I'm really looking forward to what you do with the stained glass. If you can, give us lots of detail on your technique. It is just a one man shop. I wouldn't trust anyone else enough to help me. I will let you know how I do it, but hopefully it is not bad advice since I don't know what I am doing. 1 Quote Link to comment Share on other sites More sharing options...
davewyo Posted May 20, 2017 Report Share Posted May 20, 2017 Just now, bradpotts said: It is just a one man shop. I wouldn't trust anyone else enough to help me. I will let you know how I do it, but hopefully it is not bad advice since I don't know what I am doing. Sounds good to me! You have developed a super nice pattern to start with. Quote Link to comment Share on other sites More sharing options...
wdwerker Posted May 20, 2017 Report Share Posted May 20, 2017 A helper to sweep, sand and hold the other end up does come in handy. You let them work on unseen faces and joints before they ever touch the visible work. Very nice looking door so far ! I've only done a tiny bit of stained glass, but my mother and sister did some beautiful pieces. I like clear Lexcel caulk between glass and wood. It remains flexible, cleans up with mineral spirits and prevents any rattle. Far better stuff than silicone. Quote Link to comment Share on other sites More sharing options...
bradpotts Posted May 22, 2017 Author Report Share Posted May 22, 2017 A helper to sweep, sand and hold the other end up does come in handy. You let them work on unseen faces and joints before they ever touch the visible work. Very nice looking door so far ! I've only done a tiny bit of stained glass, but my mother and sister did some beautiful pieces. I like clear Lexcel caulk between glass and wood. It remains flexible, cleans up with mineral spirits and prevents any rattle. Far better stuff than silicone. Thanks! I will have to look into the lexcel. Quote Link to comment Share on other sites More sharing options...
Tpt life Posted May 22, 2017 Report Share Posted May 22, 2017 Just in case it matters...Lexel. 30 minutes ago, bradpotts said: Thanks! I will have to look into the lexcel. 1 Quote Link to comment Share on other sites More sharing options...
bgreenb Posted May 22, 2017 Report Share Posted May 22, 2017 On 5/19/2017 at 8:06 PM, bradpotts said: . I had a long talk to myself about doing things not because they were easy but because they were right. An attitude that is becoming rarer by the day. Good on you for doing the right thing. Many (most?) people would've just kept pushing forward and hoping for the best. I always enjoy your builds, brad. Looking forward to seeing the finished product here. 1 Quote Link to comment Share on other sites More sharing options...
Bankstick Posted May 23, 2017 Report Share Posted May 23, 2017 Interesting project, to say the least. We have an exterior door from the basement to the driveway. It looks crappy and the previous owners seemed to break a pane to get inside- put a piece of glass i n and used about four pounds of caulk instead of the wood trim to hold the glass. Often thought of building a door to replace it. Thanks and will review your thread and photos for reference. 1 Quote Link to comment Share on other sites More sharing options...
bradpotts Posted May 24, 2017 Author Report Share Posted May 24, 2017 Got everything I think I need to start. I made the boarder to make sure everything stayed square. Included are: glass cutter, cutting oil, solder, running pliers, lead shears, and lead nippers. the gladd the color looks different in the light. and the lead and I think it is zink? Boarder. I guess the lead needs to be stretched. The lady at the glass store did it for me. It was basically putting it in a clamp and pulling on it. 1 Quote Link to comment Share on other sites More sharing options...
Alan G Posted May 24, 2017 Report Share Posted May 24, 2017 The door is looking great! Can't wait to see the stained glass. Quote Link to comment Share on other sites More sharing options...
treeslayer Posted May 24, 2017 Report Share Posted May 24, 2017 very nice Brad, +1 to everyone thats wanted to do stained glass, it's always something i've wanted to try. Quote Link to comment Share on other sites More sharing options...
Just Bob Posted May 24, 2017 Report Share Posted May 24, 2017 I used to do a ton of stained glass, and it looks like you are on your way. I am a little concerned with using lead in an exterior door. With lead there will be gaps between the glass and lead and depending on how well the door is protected your Colorado weather might be a problem. If its not too late look into copper foil. Using copper the joints are sealed with solder. The downsides to copper are, your cuts have to be more accurate, it will change your overall dimensions (lead vs copper foil), it is slightly more time consuming, and you will use a LOT of solder. Quote Link to comment Share on other sites More sharing options...
bradpotts Posted May 24, 2017 Author Report Share Posted May 24, 2017 I used to do a ton of stained glass, and it looks like you are on your way. I am a little concerned with using lead in an exterior door. With lead there will be gaps between the glass and lead and depending on how well the door is protected your Colorado weather might be a problem. If its not too late look into copper foil. Using copper the joints are sealed with solder. The downsides to copper are, your cuts have to be more accurate, it will change your overall dimensions (lead vs copper foil), it is slightly more time consuming, and you will use a LOT of solder. The stained glass is going to be sandwiched between two regular pieces of glass. Quote Link to comment Share on other sites More sharing options...
Just Bob Posted May 24, 2017 Report Share Posted May 24, 2017 7 hours ago, bradpotts said: The stained glass is going to be sandwiched between two regular pieces of glass. Got it, should have thought of that before typing. I have never done that, will condensation between the panes be a problem? Quote Link to comment Share on other sites More sharing options...
Popular Post bradpotts Posted June 1, 2017 Author Popular Post Report Share Posted June 1, 2017 Got started today. Made sure everything was marked and lasted out. My first cut was a long piece. It broke in the middle. Lesson learned. Next cut was better. Then started to put it together. Everything running smoothly so far. More tomorrow! 9 Quote Link to comment Share on other sites More sharing options...
shaneymack Posted June 1, 2017 Report Share Posted June 1, 2017 Very cool, Brad ! That stained glass is going to look amazing ! Sent from my SM-N910W8 using Tapatalk 1 Quote Link to comment Share on other sites More sharing options...
pkinneb Posted June 1, 2017 Report Share Posted June 1, 2017 Looking good! 1 Quote Link to comment Share on other sites More sharing options...
davewyo Posted June 1, 2017 Report Share Posted June 1, 2017 Wonderful! 1 Quote Link to comment Share on other sites More sharing options...
Woodenskye Posted June 1, 2017 Report Share Posted June 1, 2017 Brad, great job so far that is going to really make the door stand out! 1 Quote Link to comment Share on other sites More sharing options...
Brendon_t Posted June 1, 2017 Report Share Posted June 1, 2017 The door would have been very cool. Adding the shop made stained glass is going to kick it into a totally different level of awesome. I really like that though out your builds, it seems like you are constantly pushing yourself and trying new and interesting things. Keep it up Brad. 2 Quote Link to comment Share on other sites More sharing options...
bgreenb Posted June 1, 2017 Report Share Posted June 1, 2017 Looks awesome. I'm gonna have to go ahead and ask you to drop everything and finish that stained glass ASAP so I can see the finished product. Ok? Quote Link to comment Share on other sites More sharing options...
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