Woodworking is a craft that has been intriguing and captivating people for centuries. From intricate furniture to delicate wooden pieces, the possibilities are endless. In this article, we will delve into the process of making a wooden door that will never warp, a skill that any aspiring woodworker should master.
The Challenge
The journey begins with a challenge. The woodworker in the video has taken on a client with a tight deadline of just six days to create and install a barn door. Although daunting, he is determined to overcome this challenge.
Gathering Supplies
Before embarking on the project, it is essential to gather all the necessary supplies. Although the woodworker had a specific lumber in mind, he faced a setback when he discovered it wasn’t available. However, he adapted by using one-inch thick cedar stock instead of the desired two-inch thick stock. This flexibility showcases the resourcefulness and problem-solving skills required in woodworking.
To create the floating panels for the door, the woodworker cut 24 pieces of lumber, each two feet long. He then added a tongue and groove on each side to ensure a secure fit. This method is designed to accommodate seasonal wood movement, preventing the door from warping over time.
Once the lumber arrived, the woodworker carefully laid out the styles and rails to visualize the door’s construction. However, he faced another challenge when the client requested a change from floating panels to a chevron design. This change required him to visit the joiner and planer to mill the lumber accordingly.
Building the Door
Despite the time constraints and unforeseen changes, the woodworker persevered. He labeled each style and rail to avoid mistakes and meticulously cut the necessary tongues and grooves. After a dry fit test, he assembled the pieces, and with a stroke of luck, the floating panels worked perfectly when adjusted at a 22.5-degree miter.
Throughout the process, the woodworker encountered moments of doubt and stress. However, he stabilized any cracks or checks that appeared in the wood with ca glue and aptly tinted it brown to match the intended stain color. This attention to detail showcases the woodworker’s dedication to producing a high-quality and durable product.
The Hardware Dilemma
The journey wouldn’t be complete without encountering further obstacles. The woodworker received news that the sliding door hardware would be delayed, jeopardizing the completion of the project. Nonetheless, he remained focused on the task at hand and proceeded with installing the floating panels. The door came together seamlessly, ensuring it wouldn’t bind, cop, or warp.
Finishing Touches
With the project nearing completion, the woodworker allowed the finish to cure. He sprayed two coats of finish onto the door, carefully ensuring a thorough and even application. However, due to time constraints, the finish had only partially cured when the woodworker installed the door. He advised the client not to touch it until it fully cured, ensuring its longevity and preserving its beauty.
The Final Result
Despite the hurdles faced along the way, the wooden door turned out to be a remarkable success. The woodworker’s passion, skill, and determination shined through in the final result. The floating panels, initially a challenge, proved to be a beautiful and functional feature that set the door apart.
As a bonus, the woodworker also showcased other creations, including a live edge bath caddy and a reclaimed mantle. These additional pieces demonstrated the breadth of his woodworking abilities and the range of possibilities within the craft.
Conclusion
Making a wooden door that will never warp is a truly remarkable feat. It requires skill, patience, and problem-solving capabilities. The woodworker in the video demonstrated that even in the face of tight deadlines and unforeseen changes, success is possible with determination and adaptability. The finished door stood as a testament to his craftsmanship and attention to detail. Aspiring woodworkers can learn valuable lessons from his journey and apply them to their own projects.
