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insulated carriage doors

2/24/18       
Kerry Bennett Member

I am going to build insulated carriage doors for my new workshop. I saw a good archived thread from April 2010 about the construction. I am looking for detailed plans on how to build these doors. Does anyone have any suggestions on plans for insulated carriage doors? Thanks

insulated carriage doors

2/24/18       #2: insulated carriage doors ...
Geoff

Is this an overhead door or a "real" carriage door pair?

2/24/18       #3: insulated carriage doors ...
MarkB Member

Generally speaking, the detailed plans are left to the builder of the door(s) who is then responsible for said doors integrity and longevity.

2/25/18       #4: insulated carriage doors ...
Kerry Member

These will be swinging carriage doors. I understand that the builder of the door is responsible. I am wanting some detailed plans so that I can build a quality door for my workshop.

2/26/18       #5: insulated carriage doors ...
Kilgore Trout Member

Professional woodworkers make all the plans for their projects. Amateurs may also do this, as needed.

Custom made doors offer the maker and user benefits that would not be available even if there were plans.

2/26/18       #6: insulated carriage doors ...
Kerry

I will make my own plans. I was hoping that someone would share ideas on their experiences, i.e: thickness and type of insulation, type of veneer, type and thickness of frame, etc. Apparently this is not the forum for assistance.

2/26/18       #7: insulated carriage doors ...
David R Sochar Member

I thought "detailed plans" meant "detailed plans".

As you can see, this is a tough crowd. However, if you wish to post a plan of how you would go about this, others can comment on the plan, with their experience, solutions and cautions.

Size, form, species, utility, etc. Since this is most likely not for a building to house a carriage or two, will the doors be overhead sectional, overhead single, hinged outswing, or something else?

2/26/18       #8: insulated carriage doors ...
Kerry Member

Thank you for your reply. I am not sure that I would describe the previous responses as "a tough crowd". The outward swinging doors will be custom built to fit a standard 9' garage door opening. I want them to look like traditional "barn doors". The 30'x30' workshop will be heated and cooled so I want the doors to seal. They will not be opened that often. I planned on using 1" rigid insulation in a basic frame with decorative face boards. It seems many doors are 2 1/4" thick so that would make it difficult to have cedar or mahogany or whatever on the face unless they were 1/2" boards or less.

2/26/18       #9: insulated carriage doors ...
Scott

Kerry,
Just wondering if this is new construction, why not make the doors 2 1/2 inch thick? You can build all your frames to match your door thickness.

2/26/18       #10: insulated carriage doors ...
Kerry

Yes, it is new construction and I can build whatever is needed. I wonder if it would be best to use full thickness 2 1/2" material for the frame and cross members and fill in with the insulated portion vs. A frame and decorated face?


View higher quality, full size image (1298 X 823)

2/26/18       #11: insulated carriage doors ...
Kerry Member

I like a similar appearance to this picture

2/26/18       #12: insulated carriage doors ...
David R Sochar Member

I do not advise thinking in terms of a “decorated” face. Wood doors are like many architectural elements in that there is a visual language that we are comfortable with. Divided lights are familiar, as are the vertical boards. The angled rail is a diagonal stiffener that has a real function. It should not be decorative.

The style you show is a basic frame and panel design. The vertical boards usually are v-joint t&g that fit into a plow in the rail/style. You may want to evolve the design so that the v-joints do not admit water into the plows of the upper edge of any horizontal rail, hastening rot.

The frame gives the assembly its strength and the diagonal helps by triangulating the doors so they cannot sag.

The divided light area is treated like a panel and sashed, or the muntins can be fit directly into the door frame members.

Draw cross sections full size at every detail to see how it all comes together. If you have not learned to visualize, do so now.

Form follows function.

2/26/18       #13: insulated carriage doors ...
Kerry Member

I understand the tongue and groove design you describe. I think I still need to insulate the inner portion being in Indiana with potentially very cold winters. Do you agree?

2/26/18       #14: insulated carriage doors ...
Kerry Member

Any thoughts on the use use of sapele, African mahogany, Douglas fir or Western red cedar for the doors?

2/27/18       #15: insulated carriage doors ...
Geoff

A huge factor in the design and success of these doors is their exposure to the whether. If I was building these doors I would do a traditional frame and panel. Also, Hager heavy duty, ball bearing, 5x5 hinges, four/door. If you don't have some kind of hydraulic closer/opener be careful on windy days. Also, how do you plan on sealing the bottom?

3/4/18       #16: insulated carriage doors ...
Steve Member

Kerry, I'll take the liberty of humbly following in David's wake. I built a half dozen such doors while about 10" narrower in width, the issues David describes remain the same. Note the direction of the diagonal which should be evident but I seem to see the reverse error frequently. Moreso, although I am in moderate Calif weather., I used kiln dried W. Cedar, and experienced pesky shrinkage over a couple of years so keep an eye out for moisture content. But I would stay with it. I wouldn't think you want Sapele or Mahogony from a weight and expense perspective.

As to design, Google some of the custom door manufacturers specializing in such, mainly located in the PacNW for the illustrated pages and visualize as David suggested. Borrow shamelesly in ideas.

3/4/18       #17: insulated carriage doors ...
Kerry Member

Gentleman... Thank you. I believe I am going to make a standard frame with full 1 inch thick by 6 in Maple. Fill it with 1 inch rigid insulation and cover with quarter-inch Luan. I will then use three-quarter inch by 6 inch Western red cedar or African mahogany for the rails and Stiles and cross members and half inch or 3/8 inch by 6 inch boards for the filler. That would be a total thickness of 3 in for the door.

3/4/18       #18: insulated carriage doors ...
Steve Member

Kerry, you inquire about the weather/insulation situation. The Canadian WW & Home Improvement Forum has a lot of home contractors and quite a few tend to discuss your door situation under its Home Improvement Forum. Even though you and most of the fellows who have replied here are at the same general geo. latitude you will find quite a lot of cold (and colder) experience there:
https://forum.canadianwoodworking.com/forum?_ga=1.38950241.3131736.1427465266

T
here have been several identical projects posted there.

3/4/18       #19: insulated carriage doors ...
Kerry Member

Thank you!

3/4/18       #20: insulated carriage doors ...
Steve Member

Just remembered - this fellow, Jack has a thread posted on "32 feet of doors" or some such title. He's quite a craftsman on the CWW forum in Quebec, I think (cold enough for you? :) ] You can sign up for the forum, like Woodweb, and send him direct private mail. He made 32 feet plus the entire building in the course of it. He can take you from there.


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