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Other topics for members => General Woodworking => Topic started by: tule peak timber on September 15, 2019, 04:54:28 PM

Title: Building a walnut door
Post by: tule peak timber on September 15, 2019, 04:54:28 PM
I started a couple weeks ago as the wood came out of the kiln.This project will be several  more months in fabrication as some of the thicker pieces still showed internal moisture. The walnut is orchard (grafted) wood I brought in this last spring.
  The door will measure 132 inches tall 51 inches wide including an arched transom/jamb assembly.  With 3 inch thick frame, 4-5 inch thick burl raised panels - sheer weight is the main challenge. Lots of hollow form layups in the design and engineering on this build.The customer also has a massive kitchen island in the works.
(http://forestryforum.com/gallery/albums/userpics/35190/english_walnut_grafted_feb_2019.jpg?easyrotate_cache=1568579758)
 
(http://forestryforum.com/gallery/albums/userpics/35190/door_parts_8_22_19.jpg?easyrotate_cache=1568580079)
 
(http://forestryforum.com/gallery/albums/userpics/35190/DSCN2133.JPG?easyrotate_cache=1568580167)
 Note the tree graft that will be the center of the transom.
(http://forestryforum.com/gallery/albums/userpics/35190/DSCN2130.JPG?easyrotate_cache=1568580269)
 
(http://forestryforum.com/gallery/albums/userpics/35190/door_arch_1_8_29_19.jpg?easyrotate_cache=1568580410)
 
(http://forestryforum.com/gallery/albums/userpics/35190/walnut_door_1_9_15_2019.jpg?easyrotate_cache=1568580484)
 After a great deal of template router work and lamination of opposing grains for stability the layup is ready for carving today prior to assembly. Careful attention is paid to have all of these big parts floating after fabrication. Rob
Title: Re: Building a walnut door
Post by: Southside on September 15, 2019, 05:16:58 PM
WOW Rob - that is impressive!!  
Title: Re: Building a walnut door
Post by: Magicman on September 15, 2019, 06:24:49 PM
Wow, this will be interesting to follow.  Thank You for including us as you progress.  :P
Title: Re: Building a walnut door
Post by: thecfarm on September 15, 2019, 06:48:23 PM
You are one cleaver fellow to make that all work.
Title: Re: Building a walnut door
Post by: Brad_bb on September 15, 2019, 08:08:16 PM
Yes, you always seem to be doing the coolest stuff.  Is there a drawing of the door to help me visualize?  
Title: Re: Building a walnut door
Post by: Poquo on September 15, 2019, 08:18:31 PM
That's amazing can't wait to see finished product!
Title: Re: Building a walnut door
Post by: tule peak timber on September 15, 2019, 08:25:25 PM
my drawing that I'm working from. I like to keep it simple !
(http://forestryforum.com/gallery/albums/userpics/35190/walnut_door_2_9_15_2019.jpg?easyrotate_cache=1568593514)
 
Title: Re: Building a walnut door
Post by: ljohnsaw on September 15, 2019, 09:01:58 PM
 :P
So just a "small" 11' tall door... I this the front door?  Pantry? Kitchen?
Title: Re: Building a walnut door
Post by: tule peak timber on September 15, 2019, 09:10:24 PM
Yes an entry door + jamb, new construction.
Title: Re: Building a walnut door
Post by: Brad_bb on September 15, 2019, 11:17:59 PM
well, your assembly table looks big enough!
Title: Re: Building a walnut door
Post by: Texas Ranger on September 16, 2019, 11:05:41 AM
Out standing, I used to build doors, but nothing of that order.
Title: Re: Building a walnut door
Post by: Bill Gaiche on September 18, 2019, 09:20:19 AM
Simple?? Man oh man, the things you build. Awesome.......bg
Title: Re: Building a walnut door
Post by: tule peak timber on September 20, 2019, 07:13:08 PM
Progress today on sculpting the transom panels and jointing the transom round to the head. Going from round to straight is very tricky........ :) The parts are cut so I can work through the weekend for a dry fit.
(http://forestryforum.com/gallery/albums/userpics/35190/walnut_door_3_9_20_2019.jpg?easyrotate_cache=1569020901)
 
(http://forestryforum.com/gallery/albums/userpics/35190/walnut_door_1_9_20_2019.jpg?easyrotate_cache=1569020997)
 
(http://forestryforum.com/gallery/albums/userpics/35190/walnut_door_2_9_20_2019.jpg?easyrotate_cache=1569021081)
 
Title: Re: Building a walnut door
Post by: Dakota on September 21, 2019, 12:11:40 PM
I drool every time I see your shop equipment.  Love seeing your projects.
Title: Re: Building a walnut door
Post by: tule peak timber on September 21, 2019, 01:15:14 PM
I was very disappointed that Costner shut down his casino. Is the old lady holdout still running the hardware store ?
Title: Re: Building a walnut door
Post by: Dakota on September 22, 2019, 09:47:21 AM
I haven't been there in a year or so.  I trade mostly at the Twin Cities Hardware store between Deadwood and Lead on highway 385.
Title: Re: Building a walnut door
Post by: Bruno of NH on September 22, 2019, 12:37:31 PM
Following
You are the truest of craftsman  :)
Title: Re: Building a walnut door
Post by: tule peak timber on October 03, 2019, 07:53:00 PM
I kicked the guys out of the shop to get some sunshine today. Coastal live oak.
(http://forestryforum.com/gallery/albums/userpics/35190/coastal_live_oak_10_3_2019.jpg?easyrotate_cache=1570146753)
 
Title: Re: Building a walnut door
Post by: tule peak timber on October 18, 2019, 01:58:10 PM
Back building on the door this morning.Template cutting of the burl faces for the raised panels.
(http://forestryforum.com/gallery/albums/userpics/35190/DSCN2138.JPG?easyrotate_cache=1571421261)
 
(http://forestryforum.com/gallery/albums/userpics/35190/DSCN2141.JPG?easyrotate_cache=1571421312)
 
(http://forestryforum.com/gallery/albums/userpics/35190/DSCN2143.JPG?easyrotate_cache=1571421368)
 
Title: Re: Building a walnut door
Post by: tule peak timber on October 18, 2019, 07:24:13 PM
Finished sanding and oiled the transom this afternoon . I tried to show in the pics the 3-D wobble on the raised panels. Tree graft in the center.
(http://forestryforum.com/gallery/albums/userpics/35190/walnut_door_5_10_18_2019.JPG?easyrotate_cache=1571440857)
 
(http://forestryforum.com/gallery/albums/userpics/35190/walnut_door_6_10_18_2019.JPG?easyrotate_cache=1571440930)
 
(http://forestryforum.com/gallery/albums/userpics/35190/walnut_door_7_10_18_2019.JPG?easyrotate_cache=1571441004)
 
Title: Re: Building a walnut door
Post by: Southside on October 18, 2019, 07:43:34 PM
Wow - just Wow... :o
Title: Re: Building a walnut door
Post by: samandothers on October 19, 2019, 10:05:00 AM
Really great work!  The graft is so interesting.  
Title: Re: Building a walnut door
Post by: Bruno of NH on October 19, 2019, 02:22:15 PM
Yes Sir that's beautiful work!
Title: Re: Building a walnut door
Post by: tule peak timber on October 19, 2019, 07:33:34 PM
Crack filling and laying up the beefy raised panels.
(http://forestryforum.com/gallery/albums/userpics/35190/walnut_door_1_10_19__2019.jpg?easyrotate_cache=1571527788)
 Contemplating how to work through this ugly pile of slabs for the door frame and the customers kitchen island top.
(http://forestryforum.com/gallery/albums/userpics/35190/walnut_door_1_10_18__2019.jpg?easyrotate_cache=1571527953)
 
Title: Re: Building a walnut door
Post by: WDH on October 20, 2019, 07:20:53 AM
Ugly?  Oh, you mean the slabs....... ;D 
Title: Re: Building a walnut door
Post by: customsawyer on October 20, 2019, 07:32:00 AM
Very nice work Sir. Just need to get you closer so I can sell you wood. :D
Title: Re: Building a walnut door
Post by: tule peak timber on October 22, 2019, 06:56:44 PM
Tony and Jackson carved on the door panels this morning. This is going to take several days.
(http://forestryforum.com/gallery/albums/userpics/35190/walnut_door_3_10_22_2019.jpg?easyrotate_cache=1571784432)
 I started to develop the jamb legs from two of the ugly slabs. Standard "resaw and flip" reversing the grain for stability- this tames an angry tree. Once inside the slabs I was surprised at the character of the wood.
(http://forestryforum.com/gallery/albums/userpics/35190/walnut_door_2_10_22_2019.jpg?easyrotate_cache=1571784681)
 
(http://forestryforum.com/gallery/albums/userpics/35190/walnut_door_4_10_22_2019.jpg?easyrotate_cache=1571784770)
 
(http://forestryforum.com/gallery/albums/userpics/35190/walnut_door_1_10_22_2019.jpg?easyrotate_cache=1571784847)
 
Title: Re: Building a walnut door
Post by: Crusarius on October 23, 2019, 11:46:03 AM
Always amazed at how your work comes out.
Title: Re: Building a walnut door
Post by: Nebraska on October 23, 2019, 10:35:04 PM
Your projects make me remember  how amazing the gift of sight is. Thank you for the pictures. 
Title: Re: Building a walnut door
Post by: tule peak timber on October 24, 2019, 06:49:56 PM
Thanks for the kind words ! Today I started going through all of the scrap, defect cutting and prepping for finger jointing. These end jointed staves will be used for stop material and other frame parts.I hate to waste wood......
(http://forestryforum.com/gallery/albums/userpics/35190/walnut_door_4_10_24__2019.jpg?easyrotate_cache=1571957041)
 
(http://forestryforum.com/gallery/albums/userpics/35190/walnut_door_3_10_24__2019.jpg?easyrotate_cache=1571957136)
 
(http://forestryforum.com/gallery/albums/userpics/35190/walnut_door_2_10_24__2019.jpg?easyrotate_cache=1571957210)
 
(http://forestryforum.com/gallery/albums/userpics/35190/walnut_door_1_10_24__2019.jpg?easyrotate_cache=1571957367)
 
Title: Re: Building a walnut door
Post by: DWyatt on October 25, 2019, 06:58:24 AM
The head on that shaper :o :o :o
Title: Re: Building a walnut door
Post by: fishfighter on October 25, 2019, 08:53:42 AM
Just how much you think the door will weigh? :o
Title: Re: Building a walnut door
Post by: tule peak timber on October 25, 2019, 09:36:14 AM
I did some calcs before I started and the weight was scary heavy. Figure 3 inches X 48 X 108 of solid dry walnut worst case say 300 + pounds. I did an original design with hollow coring and I'm shaving even more weight as I build. I will weigh the separate parts for a close estimate before assembly.
   To answer your question- I don't know yet. 
Title: Re: Building a walnut door
Post by: Magicman on October 25, 2019, 09:55:06 AM
Beauty weighs nothing.  :)
Title: Re: Building a walnut door
Post by: tule peak timber on October 25, 2019, 10:05:41 AM
I have repeatedly advised the client that as his homes  front door, his arms will look like Popeye after use. :D 
Title: Re: Building a walnut door
Post by: btulloh on October 25, 2019, 10:12:34 AM
I have repeatedly advised the client that as his homes  front door, his arms will look like Popeye after use. :D
Hydraulic assist,   :D
Title: Re: Building a walnut door
Post by: customsawyer on October 29, 2019, 03:27:00 AM
Beautiful. 
Title: Re: Building a walnut door
Post by: ManjiSann on November 12, 2019, 09:15:09 AM
The grain on that last piece in post 26 is just amazing! Is it a finish or water to see how it would look?

This is an amazing build and I too want to thank you for bringing us along!

Brandon 
Title: Re: Building a walnut door
Post by: tule peak timber on November 12, 2019, 10:24:21 AM
The grain pic in #26 is BLO wiped on one of the "veneers" I'm developing for the frame .We pulled off of this door project for a few weeks to mill material for another job. I store the "veneers ' under cantilevered weights to keep them flat during our weather fluctuations this time of year. Juggling jobs right now !
(http://forestryforum.com/gallery/albums/userpics/35190/walnut_door_11_12_2019.jpg?easyrotate_cache=1573572218)
 
Title: Re: Building a walnut door
Post by: jbjbuild on November 15, 2019, 06:58:03 AM
Beautiful work! Very impressive and inspirational!
Title: Re: Building a walnut door
Post by: tule peak timber on February 11, 2020, 05:49:31 PM
So yesterday I dropped back in on the walnut door build by  batch cutting parts to build up the frame torsion box style. Lots of parts means proper collation and marking with chalk. The "skins" for the frame pieces came out of drying in my makeshift press looking pretty good . One advantage of a sliding saw is that multiple jigs can be set up at the same time.
(https://forestryforum.com/gallery/albums/userpics/35190/walnut_door_1_2_11_2020.jpg?easyrotate_cache=1581461216)
 
(https://forestryforum.com/gallery/albums/userpics/35190/walnut_door_2_2_11_2020.jpg?easyrotate_cache=1581461295)
 
Title: Re: Building a walnut door
Post by: WDH on February 11, 2020, 07:48:08 PM
In that last pic, that is what you will look like if you eat too much fermented squid :D. 
Title: Re: Building a walnut door
Post by: tule peak timber on April 10, 2020, 04:36:12 PM
Glue up today on the center of the door. It was about one year ago that this walnut came in as a truckload....
(https://forestryforum.com/gallery/albums/userpics/35190/walnut_door_1_4_10_2020.jpg?easyrotate_cache=1586550463)
 
(https://forestryforum.com/gallery/albums/userpics/35190/walnut_door_2_041020.jpg?easyrotate_cache=1586550561)
 
(https://forestryforum.com/gallery/albums/userpics/35190/walnut_door3_041020.jpg?easyrotate_cache=1586550687)
 
(https://forestryforum.com/gallery/albums/userpics/35190/walnut_door_4_41020.jpg?easyrotate_cache=1586550790)
 
(https://forestryforum.com/gallery/albums/userpics/35190/walnut_burls_feb_2019~0.jpg?easyrotate_cache=1586550855)
 
Title: Re: Building a walnut door
Post by: Walnut Beast on April 10, 2020, 05:56:11 PM
That Looks really nice!!!!!!!
Title: Re: Building a walnut door
Post by: thecfarm on April 13, 2020, 06:04:41 AM
That women on the right is looking at The Door the same way I am. Now that A Door!!!
Title: Re: Building a walnut door
Post by: KODAK on April 25, 2020, 02:59:17 PM
Wow this is awesome. New world Iíve never been exposed to. Can anyone give me a 5th grader explanation on why walnut is used for grafting or what purpose is served by grafting walnut? 
 More photos please!!
Title: Re: Building a walnut door
Post by: Magicman on April 25, 2020, 05:37:45 PM
To be absolutely sure what fruit/nut a tree will produce a graft has to come from a donor tree producing that fruit/nut.  Also some root systems produce better so again a known hardy "stump" is used. 

That is my 3rd grade  :P  explanation and I am sticking with it.  ;D
Title: Re: Building a walnut door
Post by: tule peak timber on April 25, 2020, 06:40:48 PM
The nut bearing top portion is actually from ancient Persia. This is  called English walnut and how it came by that name is convoluted. The nut bearing top produces large uniform, commercially viable, commercially processable nuts with which we are all familiar. The problem with the Persian (English) walnut trees is that they are susceptible to a variety of soil borne pathogens that the native CA walnut (Claro) is immune to. To get the volume and quality of nut production for a commercial operation (orchard), a couple of varieties of tops are grafted to the native CA walnut to get the best of both worlds. The older grafted trees are highly prized for gunstocks and the burls end up in the dashboards of a Mercedes Benz or a Rolls Royce . The picture below is a typical old growth CA orchard walnut tree. I will have a couple more pics of the finished door shortly. Cheers, Rob
(https://forestryforum.com/gallery/albums/userpics/35190/franquette_walnut~5.JPG?easyrotate_cache=1587854278)
 
Title: Re: Building a walnut door
Post by: Stephen1 on April 25, 2020, 08:31:43 PM
Nice door! Thanks for the explanation on grafting.
Title: Re: Building a walnut door
Post by: tule peak timber on April 27, 2020, 07:56:09 PM
First coat of colored oil today... 8)
(https://forestryforum.com/gallery/albums/userpics/35190/walnut_door_2_4_27_2020.jpg?easyrotate_cache=1588031663)
 
(https://forestryforum.com/gallery/albums/userpics/35190/walnut_door_1_4_27_2020.jpg?easyrotate_cache=1588031739)
 
Title: Re: Building a walnut door
Post by: Dan_Shade on April 27, 2020, 08:13:30 PM
Very nice. 

Do you use linseed oil? 
Title: Re: Building a walnut door
Post by: Walnut Beast on April 27, 2020, 08:28:56 PM
Looking Great 👍 
Title: Re: Building a walnut door
Post by: tule peak timber on April 27, 2020, 08:56:46 PM
Very nice.

Do you use linseed oil?
No ,not on this one. The oil is a log home finish in Oxford brown color then wiped back with rags soaked in thinner. Tomorrow morning a tie coat of a light brown burnished with a Scotch Brite pad. Both of these finishes have a UV restive component.Not my Voodo,,,but off the shelf stuff,,,, :D
Title: Re: Building a walnut door
Post by: VooDooChikin04 on May 10, 2020, 09:39:06 AM
That is a massive door and impressive work!! Amazing.