Building a Walnut Frame and Panel Exterior Door with Traditional Joinery

An overview of the process to build a large exterior door for a friend. The door is approximately 48" x 80" or 1220mm x 2032 mm. It is constructed of American black walnut using all mortise and tenon joinery, with quad, double wedged tenons for the main rails. These are wedged with purple heart. The three windows are a flemish glass insulated glass pane. The finish is hand planed, then oiled with Heritage Natural exterior oil.
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[@user-wg7dx7er8w]

Very Nice Work, I am in my 70s retired Englishman living in France, I used to have my own specialist joinery business back in the UK, And over the years I think I have made literally hundreds of doors all handbuilt and specialist windows wind, mainly barn conversions. So doors and windows were at unusual sizes, Most of my doors that I’ve made over the past years, I’ve been at least 3 inches thick, And I’ve been fitted with high security euro locks , I wish you all the success for the future, keep up the great work,

[@bizzierhythm]

I am 2 minutes in and i love this! I am building a pair of 4'x8' doors for my garage to restore its former glory and was gere for inspiration and got it! Subscribed!

[@jonathanmasson1382]

Bravo. I find everything about this door beautiful and well done.

[@mestiza1776]

That is one gorgeous door! 😍😍😍

[@marssinks8232]

incredibly beautiful!!!

[@traceoeight7549]

Love the door, it would kick ass as an inner office building door, but I don't think it will hold up long-term without providing a way for water run off. Love the looks.

[@garygilbert1526]

Your joinery and workmanship is beautiful. Installing the glass so It can't be removed ( in case of breakage) is a fatal mistake but hopefully it won't be an issue. For a door that might get some rain the panels sitting in a dado/groove will collect water and eventually rot. I use a method that avoids that; especially in gate fabrication. BRAVO to you for your great work !

[@justaguy328]

How do you do the panels so they don't collect water?

[@howardsmith5474]

I would love to see or hear how this door held up after 4 seasons of exposure. I would have been scared to apply the finish you did and not use a stave core, but I know a lot of times we over exaggerate the effects of wood movement and the environment. Plus all wood interior or exterior needs maintenance it’s simply a question of how frequently and how labor intensive that process is. Any updates?

[@the_cursor]

That is one beautiful door. Not crazy about the mauve trim but I guess it matches the stonework.

[@Knappconstruction]

Wow just wow.

[@EasterlyWilliam]

Very nice, I am interested in what kind of wood movement there will be, or how you accounted for that?

[@PopsKustojo]

Absolutely stunning this door. Thanks for sharing this build. Need this particular concept.

[@user-qs6ci3wj7t]

Mr nice wood work

[@laurentiustanea7840]

Man please don't forget about the milling footage next time! that's my favourite part by far

[@Neverstopbuilding]

Thank you, I think I legit deleted it by accident, but I just filmed a ton today for this next project and I’ll be sure to post

[@ballsdeep9648]

At the 4 minute mark you mention moving on to your grooving tool. What exactly is it? Looks like a circular saw. Thanks. And awesome door by the way. Stunning.

[@niftygriffty]

I also want to know!

[@DanBetta]

Fantastic.

[@Neverstopbuilding]

Thank you!

[@setdown2]

An exterior door with no real rain protection above...so with open tenons and places where water can get to what did you use to protect from eventual movement and water seeping in...?? Beautiful job BTW...🖖

[@JapaneseJoinery]

Nice door! Double tenons and privacy glass are perfect. I haven't tried an adjustable hole saw before, what brand is yours and do you recommend it? Also, I'm doing the same handle!

[@gte717v]

How is the door holding up? Is it still flat? So many other examples I see show laminated construction for the stiles and rails.

[@Neverstopbuilding]

My client reports that the door is still flat.

[@mfcosi]

👏🏻👏🏻👏🏻👏🏻👏🏻

[@fredbosch5392]

Beautiful door. I hope your friend changed the trim to match the door.

[@Neverstopbuilding]

I'm not sure what his plans are, oddly enough the purple heart wedges do match the existing trim.

[@suleymansekman2697]

Hmm! looking good and good craftsmanship but There is a fundamental mistake! you shouldn't use crown sawn timber exterior door! because of movement! should be quarter sawn ! Also need drip mould outside of door!

[@robertkennedy7772]

Very elegant💎💎💎!! Do what the pros do - 'Promo sm'!