Introduction: Hold That Door! a W&L-Inspired Lex Brick Creation

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Ever had a door that just won’t stay open? We did too. My roommates and I were constantly annoyed by a door that refused to stay put. But instead of using a boring old doorstop, I wanted something with personality.

If you’ve ever gone to W&L, visited W&L, or just spent time in the amazing town of Lexington, VA, you know the iconic Lex brick. So, I decided to combine art and usefulness into a project: a laser-cut, friction-fit Lex brick doorstop.

Supplies

Materials

  1. Medium draft wood
  2. Small rocks (to weigh down the box, if necessary)

Tools

  1. Laser cutter (Glowforge, Epilog, or other brand)
  2. Tweezers
  3. Sandpaper

Software

  1. Provided SVG files (Lex brick pieces + engraving)
  2. Inkscape (for editing and design)
  3. Laser cutting software such as Glowforge app

Step 1: Prepare the Design in Inkscape

Option A – Make your own design:

  1. Download and open Inkscape
  2. Use the Pen tool to draw the sides of the box in line segments (this is an easy way to trace the friction-fit edges)
  3. Tip: Hold Ctrl to create straight lines, and use copy/paste to save time
  4. Adjust dimensions using the toolbar at the top of Inkscape as pictured above
  5. Connect the lines to form the 2D drawing of the sides of your box
  6. For the top design, download a simple Lex brick graphic
  7. Import the image into an empty Inkscape file and using the Trace Bitmap tool, select Detection mode of the edge detection tool, and apply it to the image - this will provide a clearer, graphic image to work with
  8. Use the Node tool to clean up excess nodes - an image of the nodes is shown above
  9. Tip: Fewer nodes = faster engraving
  10. Export your completed SVG files

Option B – Use provided SVG files:

  1. Download the SVG file set included in this Instructable
  2. Open them in Inkscape if you’d like to make adjustments
  3. Tip: If resizing, adjust all pieces proportionally so the box still fits snugly

Attachments

Step 2: Laser Cutting With Glowforge

  1. Turn on your laser cutter
  2. Place the draft wood securely in the bed
  3. Upload your Inkscape SVG files (sides, top and bottom, and engraving)
  4. Double-check that the laser lens is clean for crisp cuts
  5. Tip: if the Glowforge preview is blurry, the laser lens should be cleaned
  6. Use the Glowforge tools to arrange the designs on the wood
  7. Place the Lex brick engraving on top of the top piece outline and adjust the sizing
  8. Tip: If scaling doesn’t work, make sure to unlock proportions in Glowforge as shown above
  9. Check the cut order → engrave first, then cut pieces
  10. Press print on Glowforge, wait for the light to glow, and push the button start your job

Step 3: Remove Pieces & Peel Film

  1. When the cut finishes, open the lid and carefully remove the board from the laser cutter
  2. Gently push out the pieces from the draft wood board
  3. Once all the pieces are removed, peel off the protective film from both sides of each piece
  4. For the engraved top piece, use tweezers to peel any stubborn tiny film bits

Step 4: Assemble the Box

  1. Fit the side pieces together to form a rectangular prism
  2. Tip: Press firmly, but not so hard you break the tabs
  3. Use sandpaper on the tight-fitting edges if the pieces won't fit together
  4. Attach the bottom piece and use sandpaper on the edges as needed
  5. (Optional) Add rocks or other weights inside if you wish to add weight
  6. Place the top piece on last, sanding edges as needed

Step 5: Use the Lex Brick

  1. Find that stubborn door
  2. Forget boring wedges
  3. Slide your Lex brick into place and admire your artsy, W&L themed doorstop!


Tips & Troubleshooting

  1. Use Inkscape rulers for alignment
  2. For a snug, seamless box: make the top/bottom slightly shorter than the side length
  3. Don’t make friction-fit tabs too thin as they can break


Customization Ideas

  1. Use a different school’s logo or symbol for your doorstop
  2. Add engravings on the sides, not just the top, to add more flare
  3. Try different woods or stains for a unique look


Final Thoughts

This project taught me how to use three new tools: the design system Inkscape, the laser cutter program Glowforge, and the actual laser cutter. Without this project, I wouldn't know how to create a 3D object out of flat pieces of wood or the importance of engraving before cutting. It’s a fun beginner-to-intermediate project that combines design with functionality—and now I have a doorstop that’s both useful and meaningful.