Knock Knock…

Knock Knock….

These jokes are typically pretty lame, but as a big office fan here is my favorite sequence of Knock Knock jokes.

“We will ask the questions!”

Anyways, recently I finished building the doors to the new workshop and I am prettttty pleased with how they turned out.

These doors ended up looking fantastic and we were able to make them for a fraction of the price of buying them. Again following the plans from Family Handyman, we were able to build the doors in a series of steps, stain them to enrich the natural color of the cedar we used, and then get them installed onto the workshop.

Step 1: Build 4 doors

Now, if you are extremely observant, think Sherlock Holmes, you may have noticed that we only have 2 doors, and yet this step is to build 4 doors. I haven’t lost my mind This is not a sign of me losing my mind, we really did build 4 doors. In order to allow for easy installation of the windows into the door frame, as well as the cedar panels on the bottom half, the plans called for each door to have 2 halves that we then glued/screwed together. By building one of those halves with a slightly wider width on all of the pieces of wood, a small ledge was created that was vital in moving onto steps 2 and 3.

Notice the small ledge created by one half of the door being slightly wider than the other.
Fantastic supervision being provided by my project manager.

Step 2: Install Panels

The paneling in the bottom half of the doors is created by using tongue and groove cedar panels. I carefully measured the length and width of the bottom opening in the door and then cut the panels to fit. With tongue and groove I have found that it is helpful to fit the pieces together when needing to measure the width, as the width can vary with how tightly you want the tongue and groove to be fit together. In this case that meant that I temporarily installed 4 panels, spaced them evenly, and then measured the remaining gap so that I could rip the 5th panel down to the correct width. I then installed the panels using wood glue and screwing through the panels into the small ledge created by the 2 halves of the door. I screwed the first two panels into place, and then installed the final 3 panels all at once. By not screwing the the last three panels until they were all slotted into place, I was able to make sure the tongue and groove spacing was even and it allowed enough flexibility in the full arrangement to get all of the panels installed relatively easily.

Midway through the panel install.

3. Install the window

This step was pretty straightforward. So straightforward in fact that I don’t have any photos from the actual install process. Everything was measured correctly, which for me is a huge accomplishment, and the window slide nicely into place in the space above the paneling of the door. Because the ledge holding the door was extremely narrow and I wanted to avoid cracking the wood frame of the window, I drilled pilot holes near the four corners of the window frame. I then used wood screws and glue to attach the window to the frame of the door. While I don’t have pictures of the process, I do have a photo of the finished product in the middle of our living room. If I had a workshop I wouldn’t have to build these things in the house….

So many things going on in this photo. A beautiful door, some disembodied hands, an intrigued kitty, and a creepy ghost reflection.

4. Stain

Stain it. Pretty straightforward, use a rag, rub it on the wood, get your mind out of the gutter, and wipe away any excess stain. In this case we chose a stain with a bit of tint to add extra protection from the elements, while sticking in the same color family as the natural cedar. I personally love the color and texture of cedar and was really happy with how the natural grain and knottyness (is this a word?) of the wood was highlighted.

Staining the wood in an extremely family friendly way. Once again, it would have been nice to have had a workshop to do this in.

5. Install those suckers

After the stain had fully dried it was time to install those suckers, AKA the doors. Family Handyman had a great tip that I definitely recommend for others in similar situations. We used a 2×4 that we screwed into the framing beneath the door as a ledge to set the doors on while installing. The 2×4 held the weight of the door while we shimmed everything into place on the sides and bottom of the door. A couple of hinges later and we had ourselves a set of doors. I’ll go into more detail regarding our door hardware/lock plan, as I think we came up with some decent solutions to security concerns I had associated with storing expensive equipment in the workshop. For now though, enjoy the finished product once more below. The roof from my last post and these doors are the two things I am most proud of in this whole build and I enjoy getting to share them with you. Thanks for reading once again!!

My project manager was very pleased with these, as am I.

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