To match and balance the grand and resplendent great room, it made sense to go bold on the front door as well.   Everything else on this project is one-of-a-kind and the front door is no exception.  To help the door stand out, there will be some interesting features incorporated into the door.

I commisioned a very talented artist, David Wassell, to make a stained-glass panel of a bull elk.  Large herds migrate, pasture, and water in close proximity to where the log home front door meets the Roosevelt National Forest.    The ‘wapiti’ are impressive animals, especially the bulls.  The largest bulls can have antlers that rise above their heads by 3 to 4 feet.   During mating season, the bull bugle and the return cow whistle is impressive to see and hear.  Visitors to our home will experience the elk majesty when entering the front door.

Stained glass bull elk for front door

Heavily textured wrought iron strap hinges will add rustic charm.   Some basic inlay patterns will be mortised into the door to add texture and depth.

The door panels consist of 3″x12″ rough sawn Douglas Fir.  I am aiming for a rough door dimension of 4′ by 8′.  Each of the 4 panels had to be planed to final door thickness of 2″.  This was accomplished by building a plunge router planer assembly at the build site.  The foundational components of the assembly consisted of rails that were leveled to support the router sled and rails that were leveled to support the panel being planed.  The rails were strips of MDF board secured to underlying bench lumber.  Each rail was leveled to the same plane using wood and steel shims.

Rails for router sled and wood door panels

After the rails were screwed down and final planar adjustments made, the router was attached to a planer sled.  The planing sled was purchased from Woodhaven.  A straight router bit was used, and each pass planed about 3/16″ of an inch.  Both sides of each panel were planed until the final thickness was 2″.

Plunge router mounted to Woodhaven planer sled

So far the panels are looking really good.  The boards still need to be jointed,  fitted with dowels,  glued up, sanded and stained.  The wood grain in the Douglas Fir looks beautiful.

I’ll document the next phases of the door construction in the next blog.

Until then,

Doug Jobe/Prosper Junction


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