Salvaged Door Shadow Box | Build It | Ask This Old House

Ask This Old House general contractor Tom Silva and host Kevin O'Connor build a shadow box using wood recycled from an old door
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Time: 5-6 hours
Cost: $100
Skill Level: Moderate
Tools List for Building a Shadow Box:
Table saw
Circular saw
Palm sander
Miter saw
Glass cutter and oil
Marker
Spray bottle
Brad nailer
Strap clamp
Shopping List:
Old wooden door
Safety glasses
Hearing protection
Work gloves
P95 or higher rated mask
60-80-100 grit sandpaper for palm sander
Wood glue
Glass
Clear glue
Brad nails
Steps:
1. Older doors may contain lead paint. Use a test kit from a home center to verify if lead is present, and if it is, you may want to have the door stripped by a professional.
2. Cut the door down to pieces using the circular saw. Use the stiles and rails as a rough guide for where to make the cuts.
3. True up the sides of the boards using the table saw.
4. Shave off the stain using the table saw. Do two passes through the saw on both sides of each board. Since this was an old door, use a P95 or higher rated mask to protect yourself from the sawdust. Once the stain is removed, the mask can be removed.
5. Use the table saw to make a rabbet cut on the edge of one of the stiles to hold the back panel. On the other side of the same stile, make a dado cut to hold the glass.
6. Sand down the back panel of the door to use as a backer for the shadow box.
7. Fill in any holes with homemade wood filler made from wood glue saw dust left over from making previous cuts. You may need to install scrap fillers into larger holes before adding the wood putty. Sand the stile and the backer with medium grit sandpaper.
8. Apply a Danish oil finish to the stile now to prevent oil from getting on the face of the miters. Dispose of oiled rags in a bucket of water to prevent spontaneous combustion.
9. Once the finish dries, cut the boards to desired length in four pieces using the miter saw. The ends can then be cut at 45 degrees.
10. Using the measurements from the boards, the backer can be cut to size with the table saw.
11. Lay the backer on top of the glass. Using the marker, trace the edges of the backer onto the glass.
12. Wearing glove, dip the tip of the glass cutter into oil, then roll the cutter along the line on the glass in one pass.
13. Turn the glass over so the traced line falls just over the edge of your work bench. Lift the glass up, then snap it down onto the table. The glass should break along the line.
14. Polyurethane glue is water activated, so dampen the miters and secure three of the four pieces together using polyurethane glue, ensuring the dado cut lines up on all three sides. Before the glue sets, finish securing the pieces with brad nails. Do not secure the fourth side yet.
15. Spray the angled cuts and apply the glue to the fourth side. Slide the glass through the dado cuts, then secure the fourth side to the rest of the frame.
16. Use a strap clamp around the box to keep it tight until the glue dries.
17. Screw the back panel to the frame with small wood screws through the rabbeted section of the frame.
Build It:
This Old House general contractor Tom Silva, This Old House host Kevin O’Connor, and special guests including Jimmy DiResta, take you through step-by-step DIY projects in this popular video series. From end-tables to cutting boards to wine racks to chicken coops and more, learn how to build from the best pros in the game. Segments include mention of all tools and materials needed to get the job done.
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Salvaged Door Shadow Box | Build It | Ask This Old House
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[@alyssanicole8559]

I grew up watching these guys and I still love watching the show as an adult. ❤️

[@MotleyStew]

The glass-snapping part was the most satisfying.

[@curtlafond2731]

"It's a piece of aht."

[@Jennyfromtheshop]

Curt LaFond Indeed, aht. 😉

[@Kauppamopo]

"it's a piece of aaaaath"

[@Nebuchadnezzar18]

Great videos, you guy's have s grest team.

[@DearHenryA]

Good job of hiding the irregular break in that second piece of glass.

[@MaximilianonMars]

I don't see it, where?

[@sambiscits6711]

I always look forward to watching their episodes, I always manage to get some tips and get a chuckle at the same time, you can't beat it.

[@justarandum7959]

Why polyurethane glue rather than wood glue?

[@JackmanWorks]

Glad to have you guys back!

[@grillo7196]

Love how they stamped the frame towards the end of this project. So simple and creative.

[@yourface8698]

You guys are awesome.

[@davidhealdjr.513]

I love how much fun they have on this show.

[@microphonixvirtualstudio1634]

I have lived sixtsix year and have never be sickone day from lead poising!!

[@dimefever1006]

I had to be the only six year old watching this on Saturday mornings.

[@Stephen1455]

Wow! You two, This Old House needs dust extraction!!!!

[@EDHBlvd]

That glass cut/break was satisfying!

[@PatFitzpatrick78]

Tommy that’s a Knife not a Sare lol

[@dashcammer4322]

I see junky old doors, and think "lumber!".

[@MoranGuyVideos]

Thanks for the video as always this is just great idea to do with an old door ...

[@atilehc7825]

What was This for? It was a CLOSED box!

[@christopherhinchee2473]

I used this video as a guide in converting an old door into a shelf display case for my knives. It came out great, but my circular saw and table saw had a hard time cutting through the 2.5" reinforced door. So, thank you for the video and the great idea!

[@espowari]

Lookin good guys! Love the new style.

[@Lxch]

I’m a simple man. I see Tom and I click the video

[@nuratdinsuleyman]

HELLO.YOU ARE THE BEST,TOMMY BOY!🤙

[@fishroombum3771]

I really enjoy watching your videos, thanks for posting. I always learn so much, just paying attention to your shop and seeing how you have it set up. It’s very efficient. Great project here! Sometimes using what you have is a great thing vs going out and throwing down $$$. Subscribed!

[@cextr]

MR Oz Well, it’s a freaking television studio. Of course everything is organized!

[@Macarthurmaintenance]

I love these videos. Do a million more just like it please.

[@MauraMcIntosh]

where do you get the branding tool used at the end?

[@abdulelkhatib2674]

1:32 the play boy license plate in the top right

[@EDHBlvd]

Nice Swisstool Tommy! Victorinox for life.

[@jayrosenberg9721]

hello. how do you make miter cuts?

[@ahmedh.mohamed5242]

Loooooooove ur channel love u guys

[@CashIsKing_UseItOrLoseIt]

nice southie accent by the sounds of it.

[@jamesbarlowjr.3762]

Very Nice! Where do you get the Branding Tool? Thanks.

[@pccalcio]

hey guys, how do you recognize lead paint ? any tricks ?

[@dylanmacdowell3824]

pccalcio you can buy a cheap test kit at home depot. Just mark the paint with it and it will turn a certain color if its lead

[@CashIsKing_UseItOrLoseIt]

pccalcio - not that this is a sure fire way to tell but i always looked at the thickness and curliness of the chips coming off.

[@JohnnySmoove]

Taste it

[@tonykuchar3237]

The dude got rid of the most interesting aspects of the old door by sanding off that unique weathered finish. That box could of had some real character.

[@donnablackman9167]

Tony Kuchar, I agree 100% !!! I couldn't believe it when he started cutting up the door then sanded all that wonderful, authentic old dark color off. We have doors exactly like that complete with glass doorknobs in our house and it was built in the late 1920's, close to being 100 years old. It's not a fancy mansion but we think It's a "Sears Craftsman" style. We're pretty sure our neighborhood houses were all from the old Sears catalogs. I was sad to see they changed a genuine antique finish into something you could walk into any store today and buy. Also, shadow boxes are never filled from the back. They have either a glass "door" on the front or the glass is inserted from a long slot across the top. You can't fill a box like the one they made from the back. It just doesn't work. Those photos would have been really striking against the old, dark finish. Okay, 'nuff of my rant. You have a good eye, Tony. Take care. :0) DBB

[@UriValdez]

Tommy is awesome

[@joshuarkristof80]

Great show but really you guys couldn't change your shirts after the pic scam.

[@rwsjrss2902]

and it is used for?????

[@tnstef2629]

Richard with his Tommy tattoo! Just solidified why he's so cool.

[@duncanmacleod7283]

What's that big grey thing in the corner. It looks like a dust extractor. Duh!

[@ericpedercini]

How do you get the stuff in there?

[@ToDoPOView]

They screwed on the back panel so it could be removed.

[@Vamp_Tepez]

Eric Pedercini yep most shadow boxes are filled just like a picture frame. Just take the back off.

[@ericpedercini]

Vamp Tepez thank you sir!

[@Brandon_Jackson]

About time they show the fucking final look!!

[@jmert_5859]

why did he throw the old rag into a bucket of watrer? that is new to me. did i miss an episode?

[@jasonjulian1]

j mert I believe it is so that the fumes coming off of the rag cannot be ignited by a rogue spark or flame.

[@jmert_5859]

Jason J appreciate the reply.

[@brandonmathiassweet3284]

A lot of finishes as they cure and take on oxygen, heat, a potential for combustion. Placing in a bucket of water eliminates that possibility.

[@Bre-nr8hg]

beautiful!

[@cc12300]

Here's the piece of glaaaaaaaaas we bought from the home center

[@cindia6697]

Is love more videos like this

[@hallowed001]

we fill screw holes with glue and chop sticks here in Hawaii

[@chriskrey310]

Do you have any videos on refinishing furniture

[@dirtroadwarrior9242]

FYI. Gorilla Glue "Clear" is not advertised as a polyurethane glue from Gorillatough.com; therefor making it a "water resistant" glue. Gorilla Glue Original and White are both polyurethane based glues which are "Waterproof" glues. I hope this helps.

[@buckhorncortez]

Thank God you've made this post...now we all can sleep at night without worrying about the glue...

[@larrydalestubblefieldthe8263]

Lol looks like a price of At (art) (Boston accent) lol

[@lebronjameslol3521]

It does look high end. Nice work.

[@microphonixvirtualstudio1634]

What does silck the glass mean?

[@iranforever2546]

God bless you all Thanks 🙏

[@dizzolve]

6:20 lol so satisfying .............

[@prakashgudimetlagudimetlap2533]

I like it your total videos

[@Ryan-rp8kf]

I'll give you a quawta faw it!

[@shahsmerdis]

can't you make a window like this? just curious, what the difference between an expensive window and this type of method?

[@brokenwave6125]

Bardia Ghajari Very little. Except i wouldnt make a window using miter joints. I'd use something more substantial

[@brokenwave6125]

Bardia Ghajari Also windows need thicker glass and ideal they will be double pane for insulation.

[@mikeabbott9748]

Tom you have a really good helper.

[@kokinkokecruz4476]

keving

[@glenwillard7537]

That was an awesome project

[@CannonSingh]

Kevin is kinda of a poser

[@CannonSingh]

Maybe his Dad is a producer

[@Ghoppa32]

My home was built in 1938 in Florida and Irma ruined my front door, I'm having trouble finding an original Replacement door or one close, you guys wanna come on down to Help and make part of the show?

[@cleroyster2610]

What kind of glue do you use?

[@Pure_KodiakWILD_Power]

bucket of water? no fireplace handy?

[@oldtwinsna8347]

It's a tv studio

[@robertbutler8004]

Here in Australia, we call that a rebate, cut not a rabbit cut!

[@lamontisabigdummy]

Rich is the better looking one

[@luketipping4721]

Took a while to stick their masks on!

[@microphonixvirtualstudio1634]

You don't need the oil, my dad never use it.

[@butchschultz3182]

Talk about the unsafe use of the table saw! I mean really?! How long is this guy been in the business? The things he does never ceases to amaze me! How did this guy ever get a job working on This Old House.

[@rapid8067]

Stfu weirdo

[@butchschultz3182]

Jack Geddes, I have no problem with you cutting your fingers off stubby. My comment was left for those who have something you lack namely intelligence. 40 years in the trades and I have seen my fair share of deleted digits. If you want to cut yours off fine, but leave shop safety to those who with a brain!

[@rapid8067]

And just how many years do you think Tom has in the trade? I don't see him with any missing fingers

[@butchschultz3182]

You just don't get it do you?!

[@KevinSmith-np6qp]

Glass panel deck railing