Today I am building a knotty alder front door for a client in Kansas City! They bought a home built in the 30's that has ties to the mob and wanted a front door that makes a statement. They want to connect to the history of the home so a speakeasy door was the natural choice. I have really enjoyed the research as well as milling my own tongue and groove knotty alder!
The door they need is 42"x 81" and is 2 1/2" thick. I am building it as a solid core with 1" cedar core and 3/4" knotty alder skins. Stay tuned for progress updates. Should only take a couple of days.
Today I built the core frame, milled all of the 1x6 alder to a T&G v joint and laminated the first side.
This photo is from the "inside" of the door.
I'm not going to lie, building a solid exterior door is no easy task. Today I laminated the 2nd side and edged the entire door slab. I plan on building the jambs today too. Here's the latest pic.
Today produced a 80" x 42" x 2-1/2" custom knotty alder door slab and a custom 6-9/16" alder jamb. Now I know why it's always been so hard to get a production crew to 5-S at the end of a long day!
Finished the knotty alder speak easy front door. This one is 2-1/2" thick and was created from custom tongue and groove knotty alder 1x6 with a solid cedar core. The strap hinges are hand forged and the jamb and threshold were both custom created from 1x8 clear alder.
I live in Austin Texas with my gorgeous wife Lisa and incredible son Hudson. I have a master's degree in mechanical engineering, and have spent the last 20 years manufacturing everything from car parts to school furniture. My passion is working alongside God to reveal the beauty that he has created!
Jon Archer - (737) 444-3339
Made with Love in Austin, Texas
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