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Morning all,
just finished this door this weekend, and thought i would get a few pics of it before it gets any in use "wear and tear". Scroll down if you want to skip the details and see the pics.
A little background, my in laws have been making wine for about 15 years as amateurs, and when i met my wife 6 years ago, they had actually gotten to a point when they were making 20 barrels per year for friends and family. (legal limit for personal use is 200 gallons per year, per household).
Anyway, we live in wine country in eastern Washington, so a small winery was the next logical step, but it couldn't be done at their location. So when my wife and I bought a house, we planted a vineyard, and have been building a large shop, with dedicated section for winery, so that when the grapes are mature enough, and we met the rest of the regs, we would be ready. We are still working on the shop ( i have pics in another post), and we are currently waiting to be annexed into the city, to get licensed, since the county is outdated and doesn't want to play with small businesses.
Anyway, as we have been waiting to get finished and licensed, my wife and her dad have continued to produce wine, and they were out of room in their starge area, so I went ahead and finished the small barrel room, ahead of the rest of the shop, so that we could keep the wine cool this summer. I did the least possible to make it cool and functional, since i haven't passed rough framing inspection yet, and the building inspector would only let me do as little as possible, and rightfully so.
I actually still need to put lights and a humidity system in, so all of the insulation and vapor barriers will have to be removed this fall, and then inspected and then redone again, then sheetrocked and the walls tiled, but the door doesn't have to be removed. Since we have our wine and a friends wine in the room, 8 barrels total, or about 2400 bottles, it was worth the hassle to put it up and down. I hope the inspector likes wine!
Now for the details. I decide to go with pine, because i bought 2 pallets of 5/8"x2" pine wainscoting, from a mill going out of business, and was planning on finishing the walls with it. I bought pre glued 24" x 60" panels from Lowes, since the wood was much nicer than any pine i could find, and would still had to glue it up.
The door is 58" wide and 84" tall. It is 1 1/2" thick pine. I built a front and rear frame both 3/4", and then sandwiched the wainscoting between them. I did the frame joints in different places on the front and rear panels, so that they overlapped for strength. I glued and screwed the front to the back. I used kreg pocket holes, and pretty much built them like large kitchen cabinet doors.
I then built the box framed for the inside of the door to contain 5" of foam insulation panels. It is constructed with pocket holes, and built just like a cabinet door as well.
I finished all the wood before final assembly with 3 coats of semi gloss minwax helmsman poly, rolled on, since the door will be subject to different temps and wash downs with water. I also wanted everything coated so that the wood wouldn't warp due to the higher humidity in the wine room.
The door weighs about 150lbs, and is hanging with three 20" strap hinges that i found on ebay for 50 bucks, including the handle. They are about 60 years old, and had to be bead blasted and painted, but much cheaper, and sturdier than what i could fine today.
I also made the removable threshold to keep the cold in, and then remove it when i need to pallet jack racks in and out. It was the only way to keep the transition smooth enough to roll 1600lbs through.
Other than the entire shop, this has been my most complicated fine wood project ever. It could have been a lot easier had i forgot about the arches and went with a square, but wouldn't have looked as cool. I could have used new hinges, so that they were all the same dimensions and not handmade almost all the same requiring shims and spacers.
I did price out a arched pine door from home depot made from pine, with out the trim, heavy hinges, finish, or insulation back, but very similar otherwise, and it was over 4000.00 dollars. I have about 400.00 in materials and probably 40 hours, but it is exactly what i needed.
After the inspector approves, i will finish the rest of the wall in the wainscoting to match what i already have under the trim.
Hope you approve!
Jesse
just finished this door this weekend, and thought i would get a few pics of it before it gets any in use "wear and tear". Scroll down if you want to skip the details and see the pics.
A little background, my in laws have been making wine for about 15 years as amateurs, and when i met my wife 6 years ago, they had actually gotten to a point when they were making 20 barrels per year for friends and family. (legal limit for personal use is 200 gallons per year, per household).
Anyway, we live in wine country in eastern Washington, so a small winery was the next logical step, but it couldn't be done at their location. So when my wife and I bought a house, we planted a vineyard, and have been building a large shop, with dedicated section for winery, so that when the grapes are mature enough, and we met the rest of the regs, we would be ready. We are still working on the shop ( i have pics in another post), and we are currently waiting to be annexed into the city, to get licensed, since the county is outdated and doesn't want to play with small businesses.
Anyway, as we have been waiting to get finished and licensed, my wife and her dad have continued to produce wine, and they were out of room in their starge area, so I went ahead and finished the small barrel room, ahead of the rest of the shop, so that we could keep the wine cool this summer. I did the least possible to make it cool and functional, since i haven't passed rough framing inspection yet, and the building inspector would only let me do as little as possible, and rightfully so.
I actually still need to put lights and a humidity system in, so all of the insulation and vapor barriers will have to be removed this fall, and then inspected and then redone again, then sheetrocked and the walls tiled, but the door doesn't have to be removed. Since we have our wine and a friends wine in the room, 8 barrels total, or about 2400 bottles, it was worth the hassle to put it up and down. I hope the inspector likes wine!
Now for the details. I decide to go with pine, because i bought 2 pallets of 5/8"x2" pine wainscoting, from a mill going out of business, and was planning on finishing the walls with it. I bought pre glued 24" x 60" panels from Lowes, since the wood was much nicer than any pine i could find, and would still had to glue it up.
The door is 58" wide and 84" tall. It is 1 1/2" thick pine. I built a front and rear frame both 3/4", and then sandwiched the wainscoting between them. I did the frame joints in different places on the front and rear panels, so that they overlapped for strength. I glued and screwed the front to the back. I used kreg pocket holes, and pretty much built them like large kitchen cabinet doors.
I then built the box framed for the inside of the door to contain 5" of foam insulation panels. It is constructed with pocket holes, and built just like a cabinet door as well.
I finished all the wood before final assembly with 3 coats of semi gloss minwax helmsman poly, rolled on, since the door will be subject to different temps and wash downs with water. I also wanted everything coated so that the wood wouldn't warp due to the higher humidity in the wine room.
The door weighs about 150lbs, and is hanging with three 20" strap hinges that i found on ebay for 50 bucks, including the handle. They are about 60 years old, and had to be bead blasted and painted, but much cheaper, and sturdier than what i could fine today.
I also made the removable threshold to keep the cold in, and then remove it when i need to pallet jack racks in and out. It was the only way to keep the transition smooth enough to roll 1600lbs through.
Other than the entire shop, this has been my most complicated fine wood project ever. It could have been a lot easier had i forgot about the arches and went with a square, but wouldn't have looked as cool. I could have used new hinges, so that they were all the same dimensions and not handmade almost all the same requiring shims and spacers.
I did price out a arched pine door from home depot made from pine, with out the trim, heavy hinges, finish, or insulation back, but very similar otherwise, and it was over 4000.00 dollars. I have about 400.00 in materials and probably 40 hours, but it is exactly what i needed.
After the inspector approves, i will finish the rest of the wall in the wainscoting to match what i already have under the trim.
Hope you approve!
Jesse
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Pat
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