Entry Door Refurbishment
Typical pre-1960’s doors are constructed of a solid pine core (c) with two plys of thin hardwood planks on each side of the door. If the weathering is minimum, the outer ply (a) can be refinished. When the weathering is more severe, the outer ply must be replaced. In really bad cases (as shown here), the deteriation extends into the inter ply (b) and even the core.
The restoration process begins with sanding off the outer ply. The inner ply and core are repaired as needed. This typically involves replacing rotten wood and stablizing sections using epoxy. New outer plys are made be cutting consecutive slices from a thick board. This results in matched wood grain across the face of the door. The plys are epoxed glued to the door. After sanding, the door is stained if applicable, and then sealed with a penetrating epoxy sealer. The door is finished with three coats of Epifane marine varnish (Epifane is a Dutch brand, recognized as the best varnish in the boating industry). The net result is a a very durable and weather proof finish.
Custom storm doors can be made to fit unique shapes. When the storm door is made to match the entry door, a stunning combination results. The above project involved refurbishing the entry door, and making a new matching storm door.