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Author Topic: Building a walnut door  (Read 4029 times)

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Offline tule peak timber

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Building a walnut door
« 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.

 

 

 Note the tree graft that will be the center of the transom.

 

 

 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
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Offline Southside

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Re: Building a walnut door
« Reply #1 on: September 15, 2019, 05:16:58 PM »
WOW Rob - that is impressive!!  
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Offline Magicman

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Re: Building a walnut door
« Reply #2 on: September 15, 2019, 06:24:49 PM »
Wow, this will be interesting to follow.  Thank You for including us as you progress.  :P
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Offline thecfarm

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Re: Building a walnut door
« Reply #3 on: September 15, 2019, 06:48:23 PM »
You are one cleaver fellow to make that all work.
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Offline Brad_bb

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Re: Building a walnut door
« Reply #4 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?  
Anything someone can design, I can sure figure out how to fix!
If I say it\\\\\\\'s going to take so long, multiply that by at least 3!

Offline Poquo

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Re: Building a walnut door
« Reply #5 on: September 15, 2019, 08:18:31 PM »
That's amazing can't wait to see finished product!
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Offline tule peak timber

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Re: Building a walnut door
« Reply #6 on: September 15, 2019, 08:25:25 PM »
my drawing that I'm working from. I like to keep it simple !

 
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Offline ljohnsaw

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Re: Building a walnut door
« Reply #7 on: September 15, 2019, 09:01:58 PM »
 :P
So just a "small" 11' tall door... I this the front door?  Pantry? Kitchen?
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Offline tule peak timber

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Re: Building a walnut door
« Reply #8 on: September 15, 2019, 09:10:24 PM »
Yes an entry door + jamb, new construction.
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Offline Brad_bb

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Re: Building a walnut door
« Reply #9 on: September 15, 2019, 11:17:59 PM »
well, your assembly table looks big enough!
Anything someone can design, I can sure figure out how to fix!
If I say it\\\\\\\'s going to take so long, multiply that by at least 3!

Offline Texas Ranger

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Re: Building a walnut door
« Reply #10 on: September 16, 2019, 11:05:41 AM »
Out standing, I used to build doors, but nothing of that order.
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Offline Bill Gaiche

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Re: Building a walnut door
« Reply #11 on: September 18, 2019, 09:20:19 AM »
Simple?? Man oh man, the things you build. Awesome.......bg

Offline tule peak timber

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Re: Building a walnut door
« Reply #12 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.

 

 

 
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Offline Dakota

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Re: Building a walnut door
« Reply #13 on: September 21, 2019, 12:11:40 PM »
I drool every time I see your shop equipment.  Love seeing your projects.
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Offline tule peak timber

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Re: Building a walnut door
« Reply #14 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 ?
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Offline Dakota

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Re: Building a walnut door
« Reply #15 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.
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Offline Bruno of NH

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Re: Building a walnut door
« Reply #16 on: September 22, 2019, 12:37:31 PM »
Following
You are the truest of craftsman  :)
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Offline tule peak timber

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Re: Building a walnut door
« Reply #17 on: October 03, 2019, 07:53:00 PM »
I kicked the guys out of the shop to get some sunshine today. Coastal live oak.

 
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Offline tule peak timber

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Re: Building a walnut door
« Reply #18 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.

 

 

 
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Offline tule peak timber

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Re: Building a walnut door
« Reply #19 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.

 

 

 
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Offline Southside

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Re: Building a walnut door
« Reply #20 on: October 18, 2019, 07:43:34 PM »
Wow - just Wow... :o
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Re: Building a walnut door
« Reply #21 on: October 19, 2019, 10:05:00 AM »
Really great work!  The graft is so interesting.  

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Re: Building a walnut door
« Reply #22 on: October 19, 2019, 02:22:15 PM »
Yes Sir that's beautiful work!
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Offline tule peak timber

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Re: Building a walnut door
« Reply #23 on: October 19, 2019, 07:33:34 PM »
Crack filling and laying up the beefy raised panels.

 Contemplating how to work through this ugly pile of slabs for the door frame and the customers kitchen island top.

 
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Offline WDH

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Re: Building a walnut door
« Reply #24 on: October 20, 2019, 07:20:53 AM »
Ugly?  Oh, you mean the slabs....... ;D 
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Re: Building a walnut door
« Reply #25 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
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Offline tule peak timber

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Re: Building a walnut door
« Reply #26 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.

 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.

 

 

 
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Re: Building a walnut door
« Reply #27 on: October 23, 2019, 11:46:03 AM »
Always amazed at how your work comes out.

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Re: Building a walnut door
« Reply #28 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. 

Offline tule peak timber

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Re: Building a walnut door
« Reply #29 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......

 

 

 

 
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Offline DWyatt

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Re: Building a walnut door
« Reply #30 on: October 25, 2019, 06:58:24 AM »
The head on that shaper :o :o :o

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Re: Building a walnut door
« Reply #31 on: October 25, 2019, 08:53:42 AM »
Just how much you think the door will weigh? :o

Offline tule peak timber

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Re: Building a walnut door
« Reply #32 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. 
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Re: Building a walnut door
« Reply #33 on: October 25, 2019, 09:55:06 AM »
Beauty weighs nothing.  :)
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Re: Building a walnut door
« Reply #34 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 
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Offline btulloh

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Re: Building a walnut door
« Reply #35 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

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Re: Building a walnut door
« Reply #36 on: October 29, 2019, 03:27:00 AM »
Beautiful. 
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Re: Building a walnut door
« Reply #37 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!

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Offline tule peak timber

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Re: Building a walnut door
« Reply #38 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 !

 
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Re: Building a walnut door
« Reply #39 on: November 15, 2019, 06:58:03 AM »
Beautiful work! Very impressive and inspirational!
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Re: Building a walnut door
« Reply #40 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.

 

 
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Re: Building a walnut door
« Reply #41 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
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Re: Building a walnut door
« Reply #42 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....

 

 

 

 

 
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Re: Building a walnut door
« Reply #43 on: April 10, 2020, 05:56:11 PM »
That Looks really nice!!!!!!!

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Re: Building a walnut door
« Reply #44 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!!!
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Re: Building a walnut door
« Reply #45 on: April 25, 2020, 02:59:17 PM »
Wow this is awesome. New world Ive 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!!

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Re: Building a walnut door
« Reply #46 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
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Re: Building a walnut door
« Reply #47 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

 
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Re: Building a walnut door
« Reply #48 on: April 25, 2020, 08:31:43 PM »
Nice door! Thanks for the explanation on grafting.
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Offline tule peak timber

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Re: Building a walnut door
« Reply #49 on: April 27, 2020, 07:56:09 PM »
First coat of colored oil today... 8)

 

 
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Offline Dan_Shade

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Re: Building a walnut door
« Reply #50 on: April 27, 2020, 08:13:30 PM »
Very nice. 

Do you use linseed oil? 
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lots of dull bands and chains

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Re: Building a walnut door
« Reply #51 on: April 27, 2020, 08:28:56 PM »
Looking Great 👍 

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Re: Building a walnut door
« Reply #52 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
persistence personified - never let up , never let down

Offline VooDooChikin04

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Re: Building a walnut door
« Reply #53 on: May 10, 2020, 09:39:06 AM »
That is a massive door and impressive work!! Amazing. 


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