Episode #7 Building a Tenon Panel Door

The Tenon Panel Door Construction process you see in this video is exclusive to Next Level Carpentry. Unique materials and joinery are perfect for modern asymmetrical doors so popular with designers and architects these days. I dig deep to show what you need to know to tackle a unique project like this... check it up if you're determined and up for a challenge!
Get 15% off all of the excellent Starbond CA glues and accelerators by entering exclusive offer code NLC at checkout here:
www.starbond.com/
And tell 'em Matt sent you...
Building a tenon panel door and need tools or supplies to get it done? Great! If you can't find what you need locally please use a link from this exclusive Next Level Carpentry Influencer's Page on Amazon:
www.amazon.com...
where anything purchased is the same low online cost you expect but Amazon pays small ad fees to this Channel which help offset cost of time spent on video production which I really appreciate... thank you!
Want to join the growing list of patrons who support Next Level Carpentry on Patreon? Excellent! Go here to check it out and join the 'above and beyond team' and see your name displayed during each new video:
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Thank you!
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So those you know know you watch this 'show'!
Here's the complete Pallet Wood Door Build Series so you can see the humble beginnings of this one-of-a-kind Tenon Panel Door:
• Pallet Wood Door Build...

[@roadrunner9949]

I refuse to build anything with fiber anything , fiber is for cereal.

[@donk9132]

@Chris Jamieson I can relate......but Matt is no fool and for this door and it's application.......tell me it ain't good enough :)

[@Maghanashi]

Shame. MDF is a very good material when used correctly. No different to hard or softwoods.

[@stevelangendoen8834]

I love what you do. "You do you best when you put your mind to it "

[@gizmobently]

Matt, as always another great job.

[@hansschultze8392]

Nothing better than waking up on a Sunday morning and a new episode of the favourite TV show is on. Watching while having breakfast. Cheers from Germany!

[@NextLevelCarpentry]

Thanks Hans! It's cool to know NLC videos have such impact and reach... hope your breakfast was delightful! Best, Matt

[@markforrestsm]

Hi Matt, have only just started watching, but had to share this thought and comment.. You talk about the "pallet wood" and then start talking about Ash that was used as pallet runners.. I WISH I could find pallet wood of that quality here at home!!! I have tears in my eyes. The stuff we get is really low-grade pine... On a better note, am looking forward to seeing the rest of the video..

[@brendanwalllis]

i learned something again... Copacetic.. thanks Matt

[@kcwoodshop59]

"CNC Carpenter Navigated Cutting" that's as close as I'll ever get to it, I dig it man and I'm totally stealing that from you!

[@Frogboy1728]

You're the funniest woodworker I watch on youtube

[@NextLevelCarpentry]

Uhmmm... is that a good thing?😏Thx Aaron! Best, Matt

[@michaelcurtis6664]

Awesome work Matt, really appreciate the hard work you've put into this build & the extra detail in the longer video format. Thanks again for your time and effort

[@richarddicktaylor219]

Fantastic work. Thank you.

[@mmlips]

You crack me up Matt. Love your channel.

[@erichenao6537]

Incredible series. Great work. One comment about something you said- Properly drilled pilot holes… Can you do a singular episode, separately, that shows in detail just exactly what you mean. That would great to see and learn. Thank you.

[@mattlane7888]

Looking forward to the next door episode installment

[@NextLevelCarpentry]

Cool... planning on doing the coved casing segment as the next NLC video upload... this coming weekend if all goes well...

[@bobsandone3108]

Both you and this project are amazing. You cold have saved a lot of time, money, and effort by going to your favorite big box store and buying a door, but you showed us all what it takes to do perfect work !!

[@NextLevelCarpentry]

Thanks Bob... it's definitely gettin' there! Best, Matt

[@michaelsopher5048]

Great job

[@mdoherty8]

I would love to see more on your use of sketch up and listen to some tips or suggestions on the best way for new users to learn the program

[@NextLevelCarpentry]

I have a whole other channel, just for you! kzbin.info/door/BWzq8RebspsaW-opjo2vxg Please keep in mind that these videos were produced a long time ago before I learned many video production methods I currently use...

[@Nolanryan1968]

Looks Great you are Master Carpenter. You have give me a lot of ideas. Thanks

[@lesliehampton5458]

I really like your "caution sign". It says so much with very few words.

[@NextLevelCarpentry]

Always gets people's attention... usually accompanied by a chuckle Leslie: teespring.com/new-caution-this-machine-has?tsmac=store&tsmic=next-level-carpentry-swag-shop&pid=663&cid=102920 Best, Matt

[@Jack-es9xq]

It's a joy to watch a master !

[@markphasey1144]

I really appreciate your attention to mentioning the important details, like the comment about remembering to cut on the line, or leave the line.

[@alasdairmackenzie515]

For myself, I very much enjoy your videos. I'm grateful for the detail you provide and the point of the exercise is to learn - for me at any rate. Many thanks from the North West of Scotland...!!

[@NextLevelCarpentry]

Yours is the most genuinely Scottish looking name I've seen, sir! You're quite welcome all the way over there in Scotland!! Best, Matt

[@davidguenther8170]

I was wondering if you were going to make your door in the same manner we made the doors for a custom log timber frame cabin, about 20 years ago. The rails and stiles were of common size...4" stiles, top and middle rail and 7" for the bottom rail. We used 5/8" MDF to fasten the finish panels to. The exterior door was Black Walnut on both sides. The interior doors were salvaged Heart Pine from an old cotton mill in Alabama, except for the bathroom doors, which were HP on the outside face and Western Cedar on the inside to match the custom vanities. It was quite an undertaking, but they turned out great. The kitchen door going out to the back deck we made out of the Cedar and as a Dutch door. I really like your videos. I kind of get amused when you say during whatever procedure you're doing, you mention the tool or product just like when a Nascar driver does during end of race interviews.

[@TheFalconJetDriver]

I am enjoying your work, I am going to build a sliding barn door for a craft room I like your ideas and the excellent explanations, as Talented as you are I have three times the experience that you do. Not because I am that much older! it just takes me three times to get the project right! with you you get right the first time. I am looking forward to the completion of this project.

[@NextLevelCarpentry]

3x experience... LOL TFJD! Best, Matt

[@anneoreilly4900]

It’s always a pleasure and inspiration watching you work. My favorite part was seeing how important that tiny out of square section mattered to the whole job. And your humor is delightful, Matt.

[@NextLevelCarpentry]

Thanks Anne.... fixing little stuff like that is rather self-serving because I'm the one who has to deal with it sooner or later and I try to follow my 'intelligence is efficient laziness' credo as often as possible! Thanks for watching and commenting... and enduring the wide range of lame-ish jokes that get tossed into the mix. Re-watching the video as I edit it I often have no idea where those things come from! 🙄😁😂😎 Best, Matt

[@lolojr1]

Nice !

[@tomtruesdale6901]

That door is already a piece of art, can't wait to see it finished

[@NextLevelCarpentry]

Work of art or not, Tom, I can't wait to see it finished either! 😂😎 Best, Matt

[@imjimimack]

@@NextLevelCarpentry I look forward to seeing you finish it, too. Episode #8, Episode #8, Episode #8...

[@NextLevelCarpentry]

@@imjimimack Saturday the 26th, Saturday the 26th, Saturday the 26th, 😁😎

[@NextLevelCarpentry]

@@imjimimack Saturday the 26th, Saturday the 26th, Saturday the 26th, 😁😎

[@NextLevelCarpentry]

@@imjimimack Saturday the 26th, Saturday the 26th, Saturday the 26th, 😁😎

[@iman-klt]

Amazing

[@lawrencerayborn6258]

Good Job Thanks

[@jamaxit]

Matt, The tip for centering a dado in the table saw easily paid for my Patreon this month. I don’t know why anyone would skip anything in your videos!

[@NextLevelCarpentry]

That's cool, James... thanks! It really helps to know what viewers, especially patrons, find valuable in videos. I just pack as much into them as possible but never know for sure what in particular resonates. 'Preciate your comment and support here! Best, Matt

[@paulburkmar6439]

Great as usual Matt. Love your humour it’s good to have a laugh.

[@jim2mckenna220]

His humor is Kiln Dry...

[@RoyBlumenthal]

Great work! That big dust-collection-wipe-away-the-tears-of-relief sniff near the end was priceless!

[@Psychlist1972]

If you mean around 34:06, I thought that was him pretending to cry because the Cardboardeur needed to be retired for good. He even joked about if afterwards. Not sure it had anything to do with dust collection.

[@RoyBlumenthal]

@@Psychlist1972 I think it was both!

[@deanwilliams93]

Starbond ordered for first time. The 2oz kit. Thanks for the discount code and link.

[@NextLevelCarpentry]

Thanks for letting me know Dean... I've yet to find something about the products, brand, service or company that I don't like. Hope you feel the same after getting and using the CA! Best, Matt

[@martyjosephson4937]

Hi Matt, nice video production, I would to take the time to thank you for your "Guy Glitter" I am using this process while making some rocking horse's for the grandkids and seems to working well, Stay safe and well!!

[@NextLevelCarpentry]

Sure beats warm water and rags, right?! Best, Matt

[@vincentdimaggio5627]

Excellent! Your attention to detail is amazing!

[@longfade]

Man, good stuff.

[@NextLevelCarpentry]

Thanks for sayin' Zach! Best, Matt

[@stashu5242]

Great series Matt. Jam packed with information as usual

[@dennisdownes9319]

Beautiful work Matt!! Thanks for reminding me of the need to ignore dumb and cruel comments from "others," and the idea that even for a very skilled professional such as yourself; THINGS TAKE TIME!!!" DD

[@danieltaylor8347]

Loving this build. Such a work of art.

[@pestpatroller]

Another great vid. I have set many a heavy door using shim to get the right alignment but nowadays I use those inflatable air wedge bags to do the job. Imagine using your hands and feet at the same time!

[@NextLevelCarpentry]

Great comment Pete.... I've got a couple of those air bag wedges and I should deploy them more often! Old dawg, new tricks? Took me awhile to get up to speed with apps and texting too but never regret newer, faster, better stuff. Thanks for watching... Best, Matt

[@edverbic7103]

Another great build! Thanks Matt 😉👍

[@NextLevelCarpentry]

Thanks Ed... with the 'little twist' I mentioned I'm really jazzed about doing the 'door palette' part soon... and then the casing! Been looking forward to that the entire time and will be curious your thoughts as those become reality... Best, Matt

[@plgard]

Thanks for sharing! The knowledge, skills, and experience are (extremely) important and it’s admirable of you (and others on KZbin) to document and distribute! Much needed, much appreciated.

[@NextLevelCarpentry]

Thanks for sayin' PLGard! Best, Matt

[@omnibuildersnz]

Lovely!!!!

[@woodlandparadise6002]

your driving my Shepard crazy while whistling during the mortise shots LOL Great video

[@mickey533]

Very cool!

[@DaveBowman345]

Really satisfying to see it all coming together... and to watch so many tricks of the trade being demonstrated is a real education. Great episode! 👍👍

[@NextLevelCarpentry]

Thanks Mr Bowman... after 7 Episodes it's FINALLY gettin' to the fun part! Best, Matt

[@gregmislick1117]

Matt, I want to thank you for this series, My wife wants a new front entry door for this pre 1840 palace we live in and I know that nothing out there is going to fit off the shelf so I was seriously considering building one myself. I still am, and thanks to this series, I feel a lot better about it - might even make it out of pallet wood ! (she might feel differently about it - there is a mill nearby where I can get nice lumber, sadly they only sell it S4S...but it sure looks nice!)

[@NextLevelCarpentry]

It's borderline hypocrisy but my choice for perfect exterior doors is.... High grade fiberglass. For thermal performance, overall durability, function and long term maintenance free longevity they can't be beat IMHO. It's what I recommend every time but will gladly defer when clients request real wood for aesthetics. That way they are aware of the comparisons. Best, Matt

[@hitechfl]

Awesome video! Exactly what I was looking to do. I appreciate you and your videos.

[@paulwright2818]

Another terrific video! There’s always something to learn watching you! I appreciate your patient effort in explaining everything you do. Cheers from Atlantic Canada 🇨🇦

[@fongfattchee777]

Nice

[@lanecobb4150]

Got my Starbond order using the NLC code a couple weeks back Matt. Already putting it to good use. 💪

[@NextLevelCarpentry]

Glad to hear it Lane... it really is a great deal on great products so no surprise it's put to good use. Barely a job goes by for me without using it at least once and usually more than once! Best, Matt

[@perrybrown4985]

I live in Australia and my solution to dust collection is to just wheel everything outside and let the dust filter down on the neighbours. Other than the middle of summer when it is miserably hot, it is nice working outside.

[@walterperrault]

AMAZING Great Video series Door is awesome Thank you so much for sharing your knowledge and skills

[@gregoryzaste5435]

Love the videos. Keep up the good work friend.

[@markforrestsm]

Master craftsman Matt! It is bloody brilliant! With the tolerances being so low, is there no danger with the wood swelling with moisture? Awesome build and looking forward to the next episode..

[@NextLevelCarpentry]

Thanks for your glowing review Mark! There's a very high and real danger of wood movement for any wood door and especially using pallet wood which is inherently unstable from the part of the tree it's cut from... that's why no sane door manufacturer would EVER use this low grade of wood. I'm skirting sensibility in attempting this but rely on a few things to go in my favor: The hinge stile is most critical where twist would be very bad so the piece is use is laminated and small in cross section. Top and bottom rails are also small in cross section and cut from vertical/rift sawn pieces that are more stable by nature. The strike stile is widest and would be prone to misbehavior (swelling and, more significant: twisting) were it not 3 pieces laminated. Many already know this but I'll add that lamination combines strengths and divides weaknesses of all 3 pieces. The chances of all three wanting to twist, cup, bow or shrink in the same direction are minimal which is what gives me confidence the door won't have unacceptable issues over time. The wood had most of a year to dry/acclimate to the shop and will be sealed with varnish when complete to minimize effects of inevitable swelling in hot and humid summer weather. Time will tell? I'm looking forward to the next couple episodes too! Best, Matt

[@markforrestsm]

@@NextLevelCarpentry Thanks Matt! Still think your "pallet wood" grade is waaaaaaay superior to anything I could get here in South Africa!..

[@NextLevelCarpentry]

@@markforrestsm I should probably appreciate the wood more than I do... it's easy to take for granted what is abundant. I'm trying to figure out what to do with what I don't use on the build... If it weren't so impractical I'd be happy to ship some of the extra pieces over to you so you could build some fun stuff! Best, Matt

[@markforrestsm]

@@NextLevelCarpentry Bless you for the thought Matt!! Take care..

[@klausreviewscraftrestore3152]

i actually made doors before with a sheet of plywood in the middle before and it lasted forever. i put skim coat on the plywood and then painted it, it was hard as a brick.

[@dr.feelgood2358]

you do fine work, and you give helpful tips! strange to use a battery powered saw in the shop, especially when it's dying. it must be your favorite saw or something.

[@davidg105]

Did you make an episode 8 and finish up this door. Just curious, I never saw the finished product and I can't find any videos past episode 7.

[@NextLevelCarpentry]

It's in the works and on the schedule for 'soon' having been delayed by a number of technical video production issues... thanks for your patience David! Best, Matt

[@ChileExpatFamily]

Love the door build. I do not have the HDF or MDF like that here in Chile so I have to use Plywood or a glue up. I am of course subscribed and have been for a while. I wish we had CA glue here in Chile. It does not exist here, and would be expensive to order it from Amazon and have it shipped here to Chile. Thanks Jim in Chile

[@NextLevelCarpentry]

Hey Jim; have you checked to see what shipping CA directly from Starbond involves? They might offer options Amazon doesn't. The NLC offer code is actually a cheaper/better deal than Amazon too. I know if I ever moved to Chile I'd bring some along with me as I can't imagine doing without it! Best, Matt

[@ChileExpatFamily]

@@NextLevelCarpentry As a veteran of the U.S. Navy I can not figure out why you are not here now. You could reduce your costs and up your income doing the same thing here:) Chile is like the 1950s. It is a first world country fr sure (Concrete highways, fiber Optic, very clean and safer than the former USA), but here we are lacking some of the products that are common and have been for years in the USA.... Gorilla glue? Does not exist here. I can order it from Amazon and pay $15 to $24 dollars a bottle after shipping. I just looked on line and I can not get anyone to ship it here........ Oh well. Thanks for the advice. I think you need to come and visit and bring a bottle or two! Jim

[@stephengray1585]

Where is Episode 8 ? I love what I'm seeing and have a lot more to go.

[@befmx31]

Man, I'd love to spend a week with you in the shop on a build.....of any kind.

[@dantrumphour3068]

As an apprentice Carpenter I am learning a lot here. 1 question, with 7" style on the latch side of the door, wouldn't you want that on the hing side for more stength at that stess point?

[@NextLevelCarpentry]

Traditional frame and panel doors ALWAYS have latch and hinge stiles of equal width Dan, for exactly the reason you question: strength. An asymmetrical style door like this requires outside the box thinking, planning, design and 'engineering' to achieve strength while breaking the mold of traditional style door design/appearance. What I achieved with the 'tenon panel' design is the strength of a solid core door so the skinny hinge stile is strong well beyond its actual dimensions because it's integral with the rest of the door. I had only to make it big enough to conceal the concealed hinges mortised into it. Hope you get to check out the other videos in this series since I packed decades worth of door making background into them to make this door. I wish you well on your carpentry journey Dan... it can be a truly fulfilling, rewarding and profitable career for those who apply themselves. Best, Matt

[@johnawhiting]

Boat Tums UP Matt :-)

[@NextLevelCarpentry]

LOL! Good one, John... thanks for makin' me smile! Best, Matt

[@gtuttle4]

Great video? Why bother with mortise and tenon if using dado completely around the door, I understand why for the rails and stiles?

[@Changtent]

Great video thanks. I wasn't sure if I should turn it off when you started talking about, "shaving the cheeks of your ash" 24:50. But I stayed and all is well.

[@patricksimons560]

They should put your machine logo on every motorbike that is made.

[@befmx31]

Matt, just wondering why you chose to use the forstner bit approach to making the mortises rather than using a router and a spiral or straight bit?

[@NextLevelCarpentry]

Ease of setup and ability to control befmx... if I were doing a LOT of these it might be worth the extra time to 'jig up' with guides, templates, etc necessary for using a router. At that I'd rather put effort into getting and using a hollow chisel mortiser since the depth of the deeper mortises would ultimately require a router bit with a CUTTING length of 3" which is too dicey for anything hand-held IMHO. I'm sure there are plenty who have a nifty plunge router set up/system for mass producing smaller mortises but for full-size door construction I just don't see it... for me anyways? Thanks for watching and commenting... Best, Matt

[@chrismoore9997]

Subscribed

[@motor2of7]

Matt, you’re a carpenter not a machinist. To measure depth with a dial caliper use the pointy end that sticks out the end of the handle. I’m always amazed by your work......you should be a machinist😁

[@rwe2156]

👍I hear you re: sawdust, but MDF is a different thing. It really is toxic. In an enclosed shop minimum dust mask and air filtration. No matter what that stuff gets everywhere and churned up when you clean, too. Narrating video is fine with me! Love you’re approach, reality and clear explanations.

[@Spheramid]

Maybe someone has commented this, but, HDF is more particle board like, with bigger chips than MDF ( medium density) which is more fibrous. Both dusty as hell. For outdoors the Miratek is awesome so far in my uses, exterior MDF sounds like a unicorn, but that stuff is great. I don't think it comes in 4x8 sheets though. The other thing I like is that it can be had in 5/4. Great vids!

[@NextLevelCarpentry]

Duane: the HDF I use is made of similar size particles as MDF. Seems to me there's no 'chips' at all but rather fine powder and a LOT of glue. There are differing grades of particleboard with varying levels of density but HDF is the hardest/densest material of its type. The brand of HDF I use is called Medex by the supplier where I buy it. I'd guess it's pretty close to the Miratek brand you describe.

[@Spheramid]

Next Level Carpentry My bad. I meant medex. But our suppliers call counter top substrate HDF. And the finer stuff Mdf.

[@NextLevelCarpentry]

@@Spheramid no 'bad' to worry about😁 There's plenty to get confused with, that's a for-sure! To my knowledge there are both high density and medium density particle board. I believe high density particleboard is for countertops and medium density particleboard is for floor underlayment and such. Then there's MDF (medium density fiberboard) and HDF (high density fiberboard) to choose from. It was only recently that I learned the HDF is made with a water-resistant/water-proof glue/adhesive where MDF is definitely not... that stuff seems to attract water for the sole purpose of disintegrating! 🙄😎

[@Spheramid]

@@NextLevelCarpentry Masonite untempered is also fiber board , it is a big field.

[@Spheramid]

@@NextLevelCarpentry The MDF sold here is sure not the same resin/glue as Medex. The HDF is just the "particle board" that has chunks and swells to 3x it's normal size when wet. Could be a geographic term ..like Kleenex or Formica used about any product that does the job. As long as it don't have vinyl wood grain contact paper on it, it all has a use somewhere.

[@hellionfi]

Thanks for the "skip over the call to actions"-tip. I understand why yt wants it in the videos, but since I've already subscribed and want to use "likes" more as personal "bookmarks" instead of messages to "The Algorithm", I appreciate the option to skip the parts that always seem a bit cringy in many videos. A "like" for that. :)

[@roar40s]

A thumbs down does the same thing a thumbs up does. KZbin doesn't care. So you can still support the channel :-)

[@lpainchaud]

Hi matt. What do you think of using a track saw to cut sheet goods in a small shop?

[@NextLevelCarpentry]

It's probably great Laurent... I don't own one and prefer my cabinet saw but suspect a good track saw wielded by a user with a bit of experience would give me a run for my money! 😉😁😎 I'm impressed by Peter Millard's 10 Minute Workshop Channel on KZbin who does remarkable things with his tracksaw! Best, Matt kzbin.info/door/_FksrzP3q-IuoWTiG501LQ

[@lpainchaud]

@@NextLevelCarpentry Thanks Matt!

[@martyfarrell9459]

3 inch bottom rails are for little girls closet doors. But, hey, if that's what you like.

[@NextLevelCarpentry]

Thanks for sharing such an ignorant comment from your work experience making closet doors for little girls' dollhouses Dirk... you're truly a paragon of consideration!

[@3125Dissent]

Matt, if your door were a true exterior door, would you still be comfortable using an HDF core? Would you take any additional measures during your "painting" process to ensure the HDF would be more sealed off? Thanks again for all of the great content you share with us!

[@NextLevelCarpentry]

Hey Patrick, the HDF panel is actually an exterior grade product called Medex made for and used by sign companies. It's pretty indestructible to my knowledge and experience so I wouldn't consider it the weak link in a chain for door durability. This door design wouldn't be good for true exterior application with all the horizontal seams, etc which would be difficult to seal against driving rain. There's no need to 'take additional measures' to protect the HDF but infiltrating water would destroy the wood from the inside out in fairly short order I suspect. That's a concern for any solid wood door construction/design though which is why, ironically, I really like the foam insulated fiberglass ones available these days from the likes of ThermaTru. Sad but true... Best, Matt

[@3125Dissent]

@@NextLevelCarpentry Matt, thanks for the detailed reply! You've more than answered my question -- but I am now debating using a stave core construction for an exterior door. The HDF core would save a lot of the headaches building a stave core involves. Either way, the main panel core will be covered by a large vertical 3/8 inch veneer on each side of the door. Again, I can't thank you enough for both the effort you put into your videos and the time you've taken to write me back.

[@NextLevelCarpentry]

@@3125Dissent I can't always reply in such detail but am intrigued when viewers like yourself ask questions that are clearly backed by a sensible thought process. Here's a bit more random perspective to consider: I've built a number of exterior doors from solid wood that have done well against the elements. Choosing good material like mahogany, white oak, doug fir etc, using Titebond III glue, laminating stiles and rails with 2 or three layers, making panels 3/4" thick and finishing with Varathane water borne exterior spar varnish are all choices that give the best chance of survival for solid wood doors. A northern exposure is actually best (better?) because the door won't ever be blasted by sun and water at the same time... those two factors are the hardest on wood and any door, regardless of quality of construction, will fail in time without annual maintenance at a minimum. Doesn't keep people from wanting them or me from building them though... Good luck with your build! Best, Matt

[@MandoFettOG]

@@NextLevelCarpentry I love fiberglass doors

[@rbyt2010]

Thanks for the video. Did you consider MDO before choosing HDF?

[@NextLevelCarpentry]

Nope... assuming by MDO you're referring to a particleboard core with a paper, plastic or melamine overlay? I have no intent that any part of the tenon panel of this door being visible when it's complete Ron. Let me know if I missed your point/question? You're welcome for the video... and thanks for watching. Best, Matt

[@rbyt2010]

Next Level Carpentry Thanks for the reply! No, the MDO I’m referring to is an exterior plywood with one or two sides covered with paper. Also used in the sign industry and for concrete forms. Thought it might be more rigid than HDF in this application, though I’m sure the HDF will be fine

[@NextLevelCarpentry]

@@rbyt2010 Oh, OK... got it. Yeah THAT MDO would be an incredibly strong/stiff/durable option, wouldn't it? I think the HDF is probably a more millwork-friendly option compared to anything with a plywood core but either would do if the other wasn't available. Thanks for watching and commenting here... Best, Matt

[@jerrystark3587]

I was trying to imagine what you were going to do with the door face by way of design using pallet wood. This made me think of the artist, George Morrison, who did some very interesting work using wood pieces. Just Google "George Morrison wood collage" and you will see what I mean. Not a suggestion; just a connection. 'Looking forward to seeing the finished door design. Thanks.

[@NextLevelCarpentry]

Thanks for the suggestion Jerry. I do have a plan in mind but it is subject to change without notice and I always appreciate new inspiration😎

[@billcarp3523]

Is there a number 8 to this series? It'd be short, but what kind of knob was used? Anyway, good job, Matt.

[@NextLevelCarpentry]

Funny you should ask Bill. I seriously just glued the door together over the weekend and installed the 'knob' so I can FINALLY finish up the panel which I think will be the next 'major' video released here at Next Level Carpentry... Best, Matt

[@billcarp3523]

@@NextLevelCarpentry Merry Christmas.

[@jakecarter2414]

Man it is coming together nicely and it looks so good. How did the meeting go with that moulder manufacturer?

[@NextLevelCarpentry]

Hey Jake, thanks for the compliment on the door... I've not felt so far out on a limb with a design in a long time so it's good to know the limb is stout. All I'll say about the moulder is that you can lead a horse to water but ya can't make it drink. Apparently not even if the pool is exceptionally cool, clear, deep and fresh... go figure? I'm still pumped about making the casing for this door though and think (hope) you'll like it too? Best, Matt

[@jakecarter2414]

@@NextLevelCarpentry well we tried, that's all we can do. I enjoy every video you put out matt. thanks for all your videos and the hard work that goes in to them, I learn something every time.

[@NextLevelCarpentry]

@@jakecarter2414 I was thoroughly impressed by audience participation in the effort for sure! Glad you like and learn from videos here... I always appreciate your engagement, comments, etc... Best, Matt

[@Kevin-jb2pv]

How's that dust collector you got treating you???

[@danbailey96]

I despise battery skilsaws at least the ones I have tried

[@MiniLuv-1984]

Can you put a second thumbs up on the video? YT, wake up from your slumber - we need multiple thumbs up please.

[@rafvdp6391]

Hey Matt another excellent video, love the details and explanation !👌 May i ask (i know HDF but it is very hard to find and i never worked with it ) is there really a ''big '' difference between HDF and MDF for this project of could MDF do the job too of would you classified that to weak ? Can't wait till the next video, greetings from Belgium.

[@NextLevelCarpentry]

Thanks raf... good question. I didn't explain it in the video but the HDF I use is actually an exterior grade product made for the sign-building industry so it's highly water resistant... almost to the point of being water proof. There's not THAT much difference in cost between it and MDF so I figure the difference is cheap insurance. Structurally, in the design of this door, I doubt there's any appreciable difference between the two. You can tell by the tone of my reply here that I didn't even compare cost since labor is such a significant factor as to make material cost irrelevant. I'm anxious to get the next phase of this door build done too! Best, Matt

[@stevelelaurin9917]

Next Level Carpentry I have always thought that HDF is that dark brown "hardboard" or Masonite product similar to pegboard without the holes. It is much harder than MDF. I have used "signboard" which was described to me as simply waterproof MDF (and, by the way, signboard is a good workbench or assembly table top). Love your videos.

[@NextLevelCarpentry]

Hey Steve, there's definitely some variation in names, product types and features/benefits that vary by region, supplier, sales outlet etc and as long as you're able to make sure you're getting the right product for the job it's all good. Never thought of signboard for a work surface but agree it sounds great for the application. Best, Matt

[@tonybowers9490]

Thanks for sharing. My sawdust collection is a broom, so you'll get no comments from me.

[@andrewfurtado0109]

Great videos just too long to watch. Keep up the good eork

[@davidgroskopf7898]

I tape over the line I’m not cutting. If you don’t see it you’re not going to cut it!

[@paulnord2013]

You should really hook up your dust collector to your file, just look at all that dust!

[@NextLevelCarpentry]

BWAHAHAHAHA!

[@conan111169]

Is episode 8 out?

[@NextLevelCarpentry]

Glad you asked... I am planning to release episode 8 where I build custom Cove casing for the pallet wood door as a live premiere this is Saturday night. Make a double batch of popcorn if you plan to join us since the video is just over an hour in length😎

[@pip5461]

Amazing result due to a lot of planing and preparation, although I didn't fully understand the extra length put on the mortises, other than a little wiggle room and perhaps wood movement through time. SOLID !

[@sdcofer52]

Phil Melson I think the extra length on the mortises was to insure a clean fit. A slightly deeper mortise doesn’t appreciably weaken the MT joint but it does make it go together easier.

[@saulgoodman2018]

Skilsaw is a circular saw, but not all circular saws are skilsaws.

[@klmbuilders5385]

Just so you know- the shirts that TeeSpring is printing have considerably smaller graphics than the shirt you're wearing in this video.

[@NextLevelCarpentry]

That's disconcerting KLM... thanks for mentioning this! I don't have an explanation since I bought my shirt from the same TeeSpring listing. Here's a link the shirt listing I used: teespring.com/new-how-you-do-anything?tsmac=store&tsmic=next-level-carpentry-swag-shop&pid=46 Take note that mine is the short-sleeve variation. It appears that the long-sleeved variations have larger text but no logo which might be the issue. I encourage you to press TeeSpring to make it right with you if you got something that differs from your expectations. Please let me know how they respond and treat you? I'm uncomfortable 'selling' stuff I don't have direct control over and my reputation is worth far more to me than any proceeds from t-shirt sales. Best, Matt

[@lucidmoses]

Is it just me of does the center piece of the door look like the cardboard? :P

[@NextLevelCarpentry]

HDF looks a lot like cardboard BUT the finished door will be... remarkable IMHO... stay tuned? 😎

[@ChristopheD_]

When you first closed the door, before you even said it, I said Oh OH..... Super nice job . Just a comment. It sure makes a difference for you, but please (if possible) do not include to much sponsored references in your videos.... From a loyal french fan!

[@klausreviewscraftrestore3152]

the way i see it, if your so scared of dust in a wood working shop, you need a different profession. my grandfather would laugh at all the crazy things people buy now because there scared into getting them by the companys, but all the companys want is your money and get it by playing on your fears. my grandfather worked in a wood shop and black smithing shop everyday almost and lived to be in his 90s, healthy.

[@irvinwittmeier5208]

Whistling should be illegal it should face the same punishment as using cardboard in a door

[@russmartin4189]

In my humble opinion, I would not make that patchwork/scrap door. It is a fad design. You see it everywhere. Anything with that much media exposure will only last a couple of years, to be replaced by something else that is the rage. You are unique. You have high level skills. I would enjoy seeing you take that junk palette wood and turn it into beautifully finished door of your own design. Anyone can cut up palettes, stain the pieces, and put them on a door, there is no doubt in my mind that you can do much better. You have come this far, now it across the finish line with something impressive.

[@NextLevelCarpentry]

I share your impression of hacked up pallets slathered with ridiculous stain/faux finishing paint and abhor much of what's 'out there'. I feel the same way about the 'ship lap' rage... they'll be burying that mess by the acre in a few years! So I anxiously await your assessment/evaluation when you see the finished Pallet Wood Door once I 'take it across the finish line' Russ. l promise it's a one-off design never seen before that will be finished to my standards. The most trendy thing about it is leaving pallet nail holes in finished pieces but that's mainly to prove the door, jamb and trim are actually made from repurposed pallets. To do otherwise would be to invite countless accusations of 'click baiting' thumbnails. Best, Matt

[@russmartin4189]

@@NextLevelCarpentry I do await your entry in the pallet wood marathon crossing the finish line. Will it be next week, or do we have to enjoy more caviar, champagne, and Baroque chamber music until she passes, when we can all cheer? When is all said, done, in the can, and published to KZbin, go ahead and fill those nail holes. I'm not going to troll you.