Client had a garden door inside a stone wall that divided the front and rear yards. It had become dilapidated over the years, so they asked me to build a new door to replicate it.
I picked up a bunch of rough white oak and got to work milling it smooth.
The curve at the top of the door had two different radii, so I had to do some math and set up an old school trammel to create the template I needed.
Gluing up the rear frame. It's held together with mortise and tenon joinery, and I used some temporary pocket screws to help hold it tight during clamping.
Next I made up a tongue and groove blank for the front face of the door.
I fabricated all the parts in my shop necessary to make a true divided lite window, just like in the original door.
After joining the two faces and sanding them down, I primed and painted the door to match the trim color of the house.
Out with the old and in the the new. I pulled the old door and transferred the hinges and hardware over to the new one.
Backyard view of the finished door.
I also fabricated a new cross bar that was missing from the original door, so that the latch would be functional once again.
The finished door as seen from the street.