Architectural Woodworking

You are not logged in. [ Login ] Why log in
(NOTE: Login is not required to post)

Doors from old barnwood

9/2/16       
Skillet Member

I have a customer that has a very nice post and beam shelterhouse next to his lake. We have put cabinets in the outdoor kitchen with barnwood doors and drawer fronts. He is putting old barnwood on the walls and would like the two passage doors to be made of barnwood as well. a 2-8 and 3-0. Any suggestions on how this might be done. My thought was to take a solid core 1-3/8" door and apply 3/8" planed barnwood to each side. I would use a commercial lock for an 1-3/4" door, I would have to cut a circle around the trim piece on the inside face of the door. I was going to plane the used barnwood down to 3/8" thick, seal the back and glue and nail the barnwood to the door. Is this feasible? The doors will not be directly exposed to the weather but subject to humidity and temperature changes. This is in the Midwest. Any suggestions on how this might be accomplished. Thanks in advance.

9/3/16       #2: Doors from old barnwood ...
rich c.

3/8" thick wood acts just like 3/4" wood if reference to wood movement. Somethings going to give if you glue it to a particle board core solid door. Wood is going to crack, or expand and lock the door into the jamb, or shrink back and have gaps that will let the solid core show.

9/5/16       #3: Doors from old barnwood ...
David R Sochar Member

Rich is correct about the 3/8" wood. Also, it is rare to see 1-3/8" solid cores built with a waterproof or water resistant glue, unless they are ordered from a custom maker.

If your customer wants barn wood, what is wrong with using barn wood? Is it suddenly going to warp after sitting out for 50 years? There are several construction styles that are primitive - that were even used on barns, amazingly enough. Board and buck doors, z braced, framed one side, lots of choices. If you aren't familiar with them, it is time to do some research.

9/5/16       #4: Doors from old barnwood ...
Joe Calhoon

It will work if you do it right. Reading your post these are interior doors right? We have done this with interior slabs. The only downside is it makes for a heavy door. Ladder core, torsion box cores and a lightweight panel material like the Sing cores are a lighter weight solution but will cost more.

The trick is to not glue the planks to each other. See picture of shiplap application. We have used splines but like the shiplap solution. The mitered edges look better but again add more cost.

We glue the planks to the core and hold position with pin nails then slip it in the vac bag. It can also work to just nail the planks on using curve cauls if the material will not flatten out. This way the planks expand independent unlike if they were edge glued together.

The thickness of you planking depends on target thickness and condition of the reclaimed wood. Here people like to see the rough face with no planing. We resaw and only plane the backside to thickness.
If the wood is warped or cupped bad planing down to 1/4" or a little less will allow it to flatten out on the core. If the wood is flat and straight you can go thicker. We use Rit dye to blend in exposed cut edges.

Every antique wood job is a little different and requires thinking outside the box. Not a job for a lean thinking shop but good for the artisan - craftsman type shop. They are usually more expensive than doors made of new wood.


View higher quality, full size image (1632 X 1224)


View higher quality, full size image (2988 X 1978)


View higher quality, full size image (1512 X 2016)

9/5/16       #5: Doors from old barnwood ...
Joe Calhoon

Building using solid wood can be done but usually requires a bit of skip planing if you can acquire flat material.
The first picture shows a solid white oak stile and rail door. We lightly flattened one face on the jointer and skipped planed the other side just enough to make a flat board. The customer has to accept the skip planing in this case.
Panel is done the same and thickness not all the same. We round and blend the edges before gluing the panel. And of course it does not fit the groove perfectly.

The idea is rustic as possible but making sure the doors operate and reasonably flat. It is a good idea to get on the same page as your customer with jobs like this explaining the risks and costs involved.

If they want a rough face on a stile and rail door we usually resaw and plane backside down to 1/4" or less. Making a stave core out of it. See last picture.

There is a good reclaimed lumber dealer here. He will de-nail and kiln dry the wood. This is important because this material is usually stored outside.


View higher quality, full size image (1512 X 2016)


View higher quality, full size image (968 X 1296)

9/6/16       #6: Doors from old barnwood ...
doug mclaren  Member

joe c, what adhesive are you using between core and barnwood "veneers"? i build in a similar method depending on look . always trying to turn out a better product. thanks. dhm

9/6/16       #7: Doors from old barnwood ...
Joe Calhoon

Doug.
We are using TB3. We have not had the issues with this glue they have been discussing here but we are not in a hot climate either.

9/14/16       #8: Doors from old barnwood ...
Brian t

I joint one face then glue the 2 plys together with west system epoxy The styles stay straight and work for cope and stick or flat panel design.

9/14/16       #9: Doors from old barnwood ...
Brian t

I forgot the most important factor to our clients. This leaves 2 rustic faces and the edges only need to be distressed to gain the aesthetics of real barn doors


Post a Response
  • Notify me of responses to this thread
  • Subscribe to email updates on this Forum
  • To receive email notification of additions to this forum thread,
    enter your name and email address, and then click the
    "Keep Me Posted" button below.

    Please Note: If you have posted a message or response,
    do not submit this request ... you are already signed up
    to receive notification!

    Your Name:
    E-Mail Address:
    Enter the correct numbers into the field below:
     

    Date of your Birth:



    Return to top of page

    Buy & Sell Exchanges | Forums | Galleries | Site Map

    FORUM GUIDELINES: Please review the guidelines below before posting at WOODWEB's Interactive Message Boards (return to top)

  • WOODWEB is a professional industrial woodworking site. Hobbyist and homeowner woodworking questions are inappropriate.
  • Messages should be kept reasonably short and on topic, relating to the focus of the forum. Responses should relate to the original question.
  • A valid email return address must be included with each message.
  • Advertising is inappropriate. The only exceptions are the Classified Ads Exchange, Machinery Exchange, Lumber Exchange, and Job Opportunities and Services Exchange. When posting listings in these areas, review the posting instructions carefully.
  • Subject lines may be edited for length and clarity.
  • "Cross posting" is not permitted. Choose the best forum for your question, and post your question at one forum only.
  • Messages requesting private responses will be removed - Forums are designed to provide information and assistance for all of our visitors. Private response requests are appropriate at WOODWEB's Exchanges and Job Opportunities and Services.
  • Messages that accuse businesses or individuals of alleged negative actions or behavior are inappropriate since WOODWEB is unable to verify or substantiate the claims.
  • Posts with the intent of soliciting answers to surveys are not appropriate. Contact WOODWEB for more information on initiating a survey.
  • Excessive forum participation by an individual upsets the balance of a healthy forum atmosphere. Individuals who excessively post responses containing marginal content will be considered repeat forum abusers.
  • Responses that initiate or support inappropriate and off-topic discussion of general politics detract from the professional woodworking focus of WOODWEB, and will be removed.
  • Participants are encouraged to use their real name when posting. Intentionally using another persons name is prohibited, and posts of this nature will be removed at WOODWEB's discretion.
  • Comments, questions, or criticisms regarding Forum policies should be directed to WOODWEB's Systems Administrator
    (return to top).

    Carefully review your message before clicking on the "Send Message" button - you will not be able to revise the message once it has been sent.

    You will be notified of responses to the message(s) you posted via email. Be sure to enter your email address correctly.

    WOODWEB's forums are a highly regarded resource for professional woodworkers. Messages and responses that are crafted in a professional and civil manner strengthen this resource. Messages that do not reflect a professional tone reduce the value of our forums.

    Messages are inappropriate when their content: is deemed libelous in nature or is based on rumor, fails to meet basic standards of decorum, contains blatant advertising or inappropriate emphasis on self promotion (return to top).

    Libel:   Posts which defame an individual or organization, or employ a tone which can be viewed as malicious in nature. Words, pictures, or cartoons which expose a person or organization to public hatred, shame, disgrace, or ridicule, or induce an ill opinion of a person or organization, are libelous.

    Improper Decorum:   Posts which are profane, inciting, disrespectful or uncivil in tone, or maliciously worded. This also includes the venting of unsubstantiated opinions. Such messages do little to illuminate a given topic, and often have the opposite effect. Constructive criticism is acceptable (return to top).

    Advertising:   The purpose of WOODWEB Forums is to provide answers, not an advertising venue. Companies participating in a Forum discussion should provide specific answers to posted questions. WOODWEB suggests that businesses include an appropriately crafted signature in order to identify their company. A well meaning post that seems to be on-topic but contains a product reference may do your business more harm than good in the Forum environment. Forum users may perceive your references to specific products as unsolicited advertising (spam) and consciously avoid your web site or services. A well-crafted signature is an appropriate way to advertise your services that will not offend potential customers. Signatures should be limited to 4-6 lines, and may contain information that identifies the type of business you're in, your URL and email address (return to top).

    Repeated Forum Abuse: Forum participants who repeatedly fail to follow WOODWEB's Forum Guidelines may encounter difficulty when attempting to post messages.

    There are often situations when the original message asks for opinions: "What is the best widget for my type of shop?". To a certain extent, the person posting the message is responsible for including specific questions within the message. An open ended question (like the one above) invites responses that may read as sales pitches. WOODWEB suggests that companies responding to such a question provide detailed and substantive replies rather than responses that read as a one-sided product promotion. It has been WOODWEB's experience that substantive responses are held in higher regard by our readers (return to top).

    The staff of WOODWEB assume no responsibility for the accuracy, content, or outcome of any posting transmitted at WOODWEB's Message Boards. Participants should undertake the use of machinery, materials and methods discussed at WOODWEB's Message Boards after considerate evaluation, and at their own risk. WOODWEB reserves the right to delete any messages it deems inappropriate. (return to top)


  • Forum Posting Help
    Your Name The name you enter in this field will be the name that appears with your post or response (return to form).
    Your Website Personal or business website links must point to the author's website. Inappropriate links will be removed without notice, and at WOODWEB's sole discretion. WOODWEB reserves the right to delete any messages with links it deems inappropriate. (return to form)
    E-Mail Address Your e-mail address will not be publicly viewable. Forum participants will be able to contact you using a contact link (included with your post) that is substituted for your actual address. You must include a valid email address in this field. (return to form)
    Subject Subject may be edited for length and clarity. Subject lines should provide an indication of the content of your post. (return to form)
    Thread Related Link and Image Guidelines Thread Related Links posted at WOODWEB's Forums and Exchanges should point to locations that provide supporting information for the topic being discussed in the current message thread. The purpose of WOODWEB Forums is to provide answers, not to serve as an advertising venue. A Thread Related Link that directs visitors to an area with inappropriate content will be removed. WOODWEB reserves the right to delete any messages with links or images it deems inappropriate. (return to form)
    Thread Related File Uploads Thread Related Files posted at WOODWEB's Forums and Exchanges should provide supporting information for the topic being discussed in the current message thread. Video Files: acceptable video formats are: .MOV .AVI .WMV .MPEG .MPG .MP4 (Image Upload Tips)   If you encounter any difficulty when uploading video files, E-mail WOODWEB for assistance. The purpose of WOODWEB Forums is to provide answers, not to serve as an advertising venue. A Thread Related File that contains inappropriate content will be removed, and uploaded files that are not directly related to the message thread will be removed. WOODWEB reserves the right to delete any messages with links, files, or images it deems inappropriate. (return to form)