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To give more character to his stay, Michel Pélegrinelli has embarked on the manufacture of a solid wood door. A quality work with personalized lines.

Manufacture of a rustic semicircular door

Level: Expert
Cost: 100 to 150 Euros (according to the origin of the oak)
Time: 40 hours
Equipment: combined wood (or at least planer-jointer), band saw (failing jigsaw), ripper, laminator, sculptor's gouges

See the plan of this realization (in pdf): Semicircular door: the plan

The door

The door consists of vertical slats in solid oak 24 mm thick (30 mm planed). They are assembled in the manner of a shutter, on three bars and two scarves of 18 x 90 mm section. These blades are also connected together by false tongues and are machined grooves of 6 x 15 mm on the edges. Also in oak, the tabs (section 6 x 28 mm) are not glued to leave the wood free to work. The back of the door is covered with a 5mm plywood panel that hides the bars and scarves. The central blade is decorated with a carved pattern with ears of wheat. exclusively for aesthetic purposes, a plinth is added on the facing side.

The modifications of the door frame

The upper part of the original frame is removed to make way for the hanger. The latter is composed of several elements in oak of 100 x 350 mm, cut of miter and assembled by slats. A stud of 18 x 50 mm cut at both ends of the curve allows precise nesting in the amounts preserved, and mortised for this purpose. A rabbet of 41 x 17 mm is machined in the extension of that of the uprights.

● Due to lack of wood of sufficient thickness, our reader has made the hanger in two laminated layers of 20 and 46 mm. We suggest you keep this process, by shifting the junction points of the elements one thickness relative to the other, so that the movements of the wood are better controlled. The assembly slats are doubled for 46 mm wood.

● The set is sealed in the opening of the partition with metal tabs. The gaps remaining on either side of the hanger are filled with plaster. On the living side, a champlat (flat molding with rounded edges) of section 18 x 64 mm covers the connection to the masonry. Its semicircular part is constituted like the hanger of several elements.

Hardware

The hinges of the old door are recovered for the new one. The upper hinge of the original frame is installed lower in a vertical part. The closing device is a rustic model, with latch and thumb. A key lock completes it. Side living, our reader has embellished the aesthetics of the door by two false hinges, one part being secured to the opening, the other of the frame.

● The realization of the opening does not present any particular difficulty. Once the blades are assembled, the door is cut to the desired dimensions. Cut to the jigsaw, the rounding is shaped to the router mounted compass.

● Do not glue the assembly tabs is not enough to leave the wood free to move since the blades are attached to the bars with two screws per connection. It is imperative to ovalize horizontally one of the two holes (on the same side of each blade for the three bars) and moderately tighten the corresponding screw.

Machining of the frame

Making the handlebars of the frame requires time and method. A template (plywood) is manufactured at the exact dimensions of the curve. Planed to desired thickness, the elements of the hanger are mitered at 22.5°. After milling the notches of the slats, they are adjusted and assembled temporarily without gluing to postpone the contour of the template. The elements are then cut roughly (with a band saw or jumper) leaving small "ears" at the ends, to facilitate tightening during bonding. The hangers are permanently assembled, then glued one on the other.

● The template is then attached to the hanger to give it its final shape to the router, with a calibrator. If you prefer to calibrate to the router, work before gluing the two halves of the hanger to mill on a smaller thickness. The internal rabbet is likewise machined at the router or router. The tenons are cut with a band saw, or cut with a jigsaw and sharpened with a chisel.

Parties taken aesthetically

Parties taken aesthetically

A trained eye immediately understands that the hinges are fictitious: logically they can not be on the side of the thumb.
The plinth attached to the base of the door would normally be used for the flow of water, a useless function for an interior door except to want to simulate a retrieved exterior door. If you copy this door, opt instead for sobriety: the carved pattern and the thumb latch are enough to give it cachet.

The dormant

The dormant

The hanger is made from a template plotting and plywood machining at the exact dimensions of the hanger, the cutting of this template is performed at the router installed in a compass.

Train the hanger

Train the hanger

Several elements assembled by slats form the hanger. In addition to the semi-circular part in four pieces, two complementary parts allow the connection with the verticals.

Useful "ears"

of the

When cutting to trim elements of the hanger, "ears" are left at the ends. They allow the easy and effective positioning of clamps during bonding.

Assemble the hangers

Assemble the hangers

Two hangers are manufactured. They will be glued to form one and get the desired total thickness. Final shaping is done at the router (sizer) or router.

Seal the hanger

Seal the hanger

The hanger replaces the upper part of the original door jamb. Connected to the uprights by a tenon, it is sealed with plaster (by metal legs) in the partition, cut accordingly.

The door and its assembly

The door and its assembly

Rigidified on the back by three bars and two scarves, the assembly by false tongues composes a structure similar to that of a shutter. Rigging parts allow the hardware to be installed.

Lay a plywood

Lay a plywood

Bars, scarves and wedges are concealed under a 5 mm plywood, nailed with small tips to man's head. The panel is then tinted in the same tone as the whole.

Install a traditional closure

Install a traditional closure

To enhance the rustic look, our reader has equipped the door with a traditional latch and thumb closure.

Another interest: avoid the installation, more complex, of a lock to larder.

Ornamental elements

Ornamental elements

Fictitious hinges are added to the door siding. Available in DIY stores, they are cut to allow opening by pushing.

A rustic pattern

A rustic pattern

Without being complex, the rustic carved pattern requires some control of the gouges. It is here cleared hollow (the high parts of the pattern are at the same level as the rest of the blade).


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