Thursday, March 31, 2016

Custom Project: Beveled Glass Exterior African Mahogany Door

By Gretchen Sawatzki

The projects are endless at Materials Unlimited and some of our favorites include custom door projects. With a little imagination it's easy to take an old beveled or stained glass window, and insert it into an exterior door for a unique look.

Custom-fabricated African mahogany door.
Image by Charles Wiesner

This door project started with a custom-fabricated African mahogany door built to a custom width of 38 inches.

White paint is added to the interior side of the door.
Image by Charles Wiesner

Since our customers were looking for a painted interior and a stained exterior for their door color-matched the white paint to coordinate with the customer's existing paint on the interior of their home. We applied two coats of paint, leaving plenty of time between each coat to dry, followed by a light sanding before the second application.

First coat of chestnut stain is applied to the exterior side.
Image by Charles Wiesner

Once the interior side of the door had been painted, it was time to move on to the exterior side. Our customers were looking for a dark chestnut stain to match existing decorative elements in the home. The first application is laid and left to thoroughly dry before adding the second coat making sure to coat the moldings with an even consistency.

Stain is colored-matched to the armchair before the first
layer of polyurethane is applied.
Image by Charles Wiesner

Once the stain had been properly colored matched, we applied the first layer of polyurethane. It's important to allow the polyurethane enough time to dry before sanding and applying the next coat.

The final layer of polyurethane is applied and left to dry.
Image by Charles Wiesner

The second layer of polyurethane is added to make the stain really pop! The polyurethane not only adds a luster, but it also acts as protectant and sealer on the exterior of the door making this a low-maintenance door!

Weather stripping is added to the inside cavity of the door.
Image by Charles Wiesner

Once the polyurethane has dried on the exterior side of the door, weather stripping is added the edge of the inside cavity to create a seal between the wood of the door and the glass insert.

Wooden stilts are placed within the cavity to hover the glass
insert during installation.
Image by Charles Wiesner

After the weather stripping had been applied, wood stilts are positioned within the door cavity to place the tempered glass panel evenly without cracking it. Without the aid of the stilts the glass could be cracked upon installation.

Tempered glass unit is installed.
Image by Charles Wiesner

The tempered glass is strategically placed within the door's cavity atop the stilts for safe installation.

Tempered glass unit is cleaned.
Image by Charles Wiesner
The tempered glass insert is thoroughly washed and cleaned of any dirt or grime in preparation to place the heavy beveled glass insert.

Beveled glass panel and moldings are installed.
Image by Charles Wiesner

The beveled glass panel is careful laid in place atop the tempered glass insert and the finishing moldings are put into place.

Finished interior side of the door.
Image by Charles Wiesner

Once the moldings on the interior side of the door are put into place the door is finished and ready for installation!

Finished exterior side of the door complete with
low-maintenance polyurethane coating,
Image by Charles Wiesner
This custom door project is a great low-maintenance option for any home. With a custom design and polyurethane coating this door will last for several decades with need to refinish the door!

If you're interested in a custom door project stop by our brick-and-mortar store at 2 W. Michigan Avenue, Ypsilanti, Michigan for details on design options, custom retrofits, and pricing.

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