WINNER
This double sided woven Rosewood door panel was made using hand selected Forest Stewardship Council (FSC) certification supplied heart timber. The door has been mounted on a soft close, hold open, Fritz Jurgen pivot. The design intention was a seamless appearance from both sides. The door contains a brush seal on the same plane all round and on the underside of the door the seal sits atop and behind an alloy high hat channel 4mm up from FFL which is drained into an Allproof drain. It is raised so a wet TS 48 Fin seal does not wipe the floor leaving moisture on opening after a storm. The rest of the frame’s side lights are standard joinery, also in Rosewood. All hidden surfaces have been treated with epoxy sealer and the frame sits on DPC, installed so it is invisible, see the detail. The design was drawn in 3D Autocad with several selections of daylight size of the aperture for the client’s approval and a sample corner then made to be sure.
Having constructed the door in an Autocad drawing made the process of the build easier. After supplying drawings of each component and the how the door was constructed, the assembly could be worked out. This was a much considered design. The “trellis” half checks were made with a dado and accurately finished with a router. Bandsaw templates made from printed full size paper print outs from the Cad drawings. Jigs were made to the side elevation of the wave dimension radius for the spindle moulder work, to smooth out the face after cutting the marked out form. The waves were then smoothed on a bobbin sander. The styles, top and bottom rail were housed to accept the made up wave panel, and then Resorsinol glue was used to join into one solid panel on the perimeter timbers, being sure all grains are carefull matched. The back of each panel was then epoxy seal coated before glueing to 10mm toughened glass using a combination of 3M double sided tape and urethane. The major difficulty was designing the door, made old school, without the aid of CNC,and designed to be water tight within a minimum width utilizing 150 x 50 timber, with a desire to keep the door lighter, and also to allow sufficient timber to fit the Fritz Jurgen and lock in a thick part of the door plus to run the seals on the same plane around the door, accurately made for this door to survive storms like cyclone Gabrielle, where the door’s water tightness proved successful with no ingress of water. The whole process of cad time, samples, manufacture, etc was more than 450 hours.
