WoodZest
Custom Furniture & Woodworking Studio

Entry & Storm Doors

Custom storm doors and refurbishment of entry doors returns the beauty and curb appeal of classic older homes. Your entry door is refinished or reclad with new wood, bringing it back to its original glory. A custom storm door can be built to complement the entry door. In particular I can make non-standard door shapes (round top, oval top, etc.).

Entry Door Refurbishment

Before - A very badly deteriorated entry door

Before - A very badly deteriorated entry door

 

Typical pre-1960’s doors are constructed of a solid pine core (c) with plies 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 (reclad). In really bad cases (as shown here), the deterioration 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 stabilizing 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 epoxied 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 weatherproof finish.

After - A refurbished door brings beauty back to a classic home

After - A refurbished door brings beauty back to a classic home

 
 
Sanding off the outer ply

Sanding off the outer ply

Repairing inner ply and core

Repairing inner ply and core

New plys cut from a single board

New plys cut from a single board

Typical entry door construction A) Outer Ply B) Inner Ply C) Solid Core

Typical entry door construction A) Outer Ply B) Inner Ply C) Solid Core

Gluing on new plys

Gluing on new plys

 

Storm Doors

Before - An ugly aluminum storm door that doesn’t fit the shape of the entryway or the character of the house

Before - An ugly aluminum storm door that doesn’t fit the shape of the entryway or the character of the house

Before - A battered and ill fitting 80 year old original storm door.

Before - A battered and ill fitting 80 year old original storm door.

After - A new storm door and refurbished entry door compliment this unique entryway

After - A new storm door and refurbished entry door compliment this unique entryway

After - A new oak storm door, made in the original classic style. The original wood on the entry door was also refinished.

After - A new oak storm door, made in the original classic style. The original wood on the entry door was also refinished.

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 projects involved refurbishing the entry door, and making a new matching storm door.