So because I'm apparently an idiot, I thought this project would take just about 2 weeks.  2 months later, I am sick and tired of end grain, but I have what I think is a pretty kick ass door.  I made it at Tech Shop (and thank god I had Tech Shop because otherwise, this damn thing would have taken 5 times as long to make)  http://Techshop.ws

Step 1: Cut a bunch of 2x4s

Using the miter saw, I cut down about 12, 8' 2x4s.  This gave me approximately 4 million 2.5" pieces.   
How do you plan to deal with the expansion and contraction of the door with changes in humidity?
Nice. You ought to post a photo with finish on it, so we can get see full effect of all that interesting end grain. Looks like it will be awesome.
this is incredible!!!
Heh, I like it ;-) Did you bother to joint/plane the pieces before cutting? <br>I'd love to see a photo of the final installed door.

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