Custom Furniture & Woodworking Studio

Entry Door Refurbishment


The function of the tools I use and how they work are explained here. Specific tools used are noted in bold.

The exterior plies are resawn (cut parallel to the face) from a thick board on the bandsaw. All plies are laid out side by side, which results in matching grain pattern. The pieces are taped together prior to glueing. The seams are glued by unfolding the taped joints and injecting epoxy with a syringe. Epoxy is rolled on the surface or the plies and the door, and the door is placed is the vacuum bag. When the air is pumped from the bag the atmospheric pressure clamps the plies to the door while the glue dries. The atmosphere exerts 14.7 pounds per square inch, so when the door is under vacuum there is approximately 42,000 pounds of pressure pressing the plies to the door. Because of this high pressure the voids where the window panes were must be temporarily filled to prevent crushing.

After the glue dries overnight the door is taken out of the bag. The first step is to peel off the tape and sand the door. The plies were cut oversize so they overhang all edges. They are trimmed back flush to the edges using a flush trim bit in the router. The flush trim bit has a bearing that is the same diameter as the cutter blade. As the bearing rides along to door the plies are cut flush. The sections by the window mullions are cut by hand. The last step is to route the v-grooves between the plies.

Craig JentzWoodZest