Passage and entry door construction

      Step-by-step descriptions and photos of the process. August 9, 2001

Photos and text by Jim Davis


Shop 1


Shop 2


Shop 3


Shop 4


Staves glued and clamped.
We rip and glue up a core of poplar 1x2's with the grain alternating direction, plane the cores to size and then glue a 1/4" veneer of the finish wood on the face.


Tim Wiser.
Tim was instrumental in getting the door shop underway.


A closeup of the stiles being glued and clamped.


Gluing up a door.
After jointing and planing the stiles and rails, they are run through the shaper to cut the cope and stick profile. They are then drilled and doweled before final assembly.


Door assembled and clamped.


Planing away.
The finished door is planed and sanded before sending to the jobsite.


Tim smooths a door edge.


Sid and the Trammel.
Sid and I (Wendy's Dad) made a curved top door and sidelight out of red oak. We laid all the dimensions out full scale on the plywood and then used a trammel-mounted router to cut the casing used to trim the door.


Close up of the trammel.


Gluing up the jamb.
We had to build a curved head jamb to match the door. We ripped 1/4" thick strips of red oak and glued and clamped them back together on a curved caul.


Jim and Wendy and the finished door.
This door has glass panels and is in an office.



Would you like to add information to this article?
Interested in writing or submitting an article?
Have a question about this article?


Have you reviewed the related Knowledge Base areas below?
  • KnowledgeBase: Architectural Millwork

  • KnowledgeBase: Architectural Millwork: Custom Millwork

  • KnowledgeBase: Architectural Millwork: Doors and Windows

  • KnowledgeBase: Woodworking Miscellaneous

  • KnowledgeBase: Knowledge Base


    Would you like to add information to this article? ... Click Here

    If you have a question regarding a Knowledge Base article, your best chance at uncovering an answer is to search the entire Knowledge Base for related articles or to post your question at the appropriate WOODWEB Forum. Before posting your message, be sure to
    review our Forum Guidelines.

    Questions entered in the Knowledge Base Article comment form will not generate responses! A list of WOODWEB Forums can be found at WOODWEB's Site Map.

    When you post your question at the Forum, be sure to include references to the Knowledge Base article that inspired your question. The more information you provide with your question, the better your chances are of receiving responses.

    Return to beginning of article.



    Refer a Friend || Read This Important Information || Site Map || Privacy Policy || Site User Agreement

    Letters, questions or comments? E-Mail us and let us know what you think. Be sure to review our Frequently Asked Questions page.

    Contact us to discuss advertising or to report problems with this site.

    To report a problem, send an e-mail to our Webmaster

    Copyright © 1996-2017 - WOODWEB ® Inc.
    All rights reserved. No part of this publication may be reproduced in any manner without permission of the Editor.
    Review WOODWEB's Copyright Policy.

    The editors, writers, and staff at WOODWEB try to promote safe practices. What is safe for one woodworker under certain conditions may not be safe for others in different circumstances. Readers should undertake the use of materials and methods discussed at WOODWEB after considerate evaluation, and at their own risk.

    WOODWEB, Inc.
    335 Bedell Road
    Montrose, PA 18801

    Contact WOODWEB











  • WOODWEB - the leading resource for professional woodworkers


      Home » Knowledge Base » Knowledge Base Article