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Home made hardwood door and ledgestone entry

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Picture of Home made hardwood door and ledgestone entry
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So apologies in advance - when I originally did this project a few years ago I failed to take some initial pictures of the build.
So to set the scene, I was most unhappy with our current front door and entrance to the house.
I went through all the usual options i.e. looking at factory made doors etc but as it turns out my house has a non-standard door frame for Australian houses... it's 30mm skinner and ~200mm higher. Having a custom door made would have cost me easily upwards of $2000 even for a basic sturdy door.

To further enhance the front entry I decided to cover the existing wooden and brick entrance with some pretty ledgestone.

Again apologies if I dont have all the steps document.

Here we go
 
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Step 1: Laying the Foundation

Picture of Laying the Foundation
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Firstly this was the first door I ever attempted and everything was done in my garage using pretty much standard electrical hand tools.

At the time I had just had Australian Jarrah flooring laid in the house to replace the horrible carpet in our first house.
Thankfully I had some lenghts of flooring timber already in the garage (complete with tongue and groove) I knew I didnt have enough but luckily my friend who did the timber floors always ends up with various cuts of hardwood laying around so I managed to collect enough to cover the job.

So I started with a sheet of Marine Plywood that I cut to the right size (the dimensions of the frame i the thickness of the boards (12mm) around the whole thing (so I could frame it with jarrah too)
To cut it to size all I used was a standard drop saw.

After cutting the sheet to size I cut the groove away from the first board and top nailed that to the plywood (note at every step I used flooring glue to secure the timber to the plywood)

After setting the first board I used what australians call a 'secret nailer' basically it's a nail gun that fires small nails at a approx 45 degree angle through the tongue of the timber.

Using one of these means the end result is that no nails are seen except for the first and end piece that are top nailed.

The picture attached is when I had laid a fair few boards and cut the hole where the dual glazed glass was supposed to go.

flyfinn1980 (author) 1 year ago
you're welcome. i think it took me about 4 weekends for the door due to the cold making things dry a lot slower. as forcthe ledgestone I think total 2 days again becausevi only did 3 rows at a time to stop things moving from the weight
dvfco1 year ago
That's very beautiful work. I think I'd need quite a while to get the job done, but I'd love the challenge. Thank you for posting it,
Very nice!