|The starting point... a century old door in need of some attention.|
Then in Part Two, I pulled the door's frame and panels apart and then re-built it.
Now, in this third part of the saga, the bolection moulds will be repaired and affixed to the face of the door as the top panels are prepared for the addition of leadlight windows, replacing the arched timber panels. Such a challenge and privilege to have the responsibility of breathing new life into this door!
Matching the profile to make more mouldings.
Below thick layers of old paint, the bolection moulds have a complicated profile. My task was to make new mouldings to replace the missing or damaged sections. The starting point was to work out the geometry of the original mouldings so that I could make new moulding sections as close a match as possible.
|Under the paint lies some interesting geometry. I had to match it.|
|Choose your weapons!|
|This "Half-Round" plane is a winner on this section.|
|This Hollow is a winner too.|
|Another pair of Hollows and Rounds are a good fit too.|
The essential thing to understand regarding the use of moulding planes is laying the foundations first - the rebates and chamfers. The best book on this subject that I have come across was published a couple of years ago, by Lost Art Press in the USA.
|Matt Bickford, you are a legend. This book is brilliant.|
I started by machining the timber to the required starting point - 76mm x 22mm (3" x 7/8"). I used a router cutter to cut one small Roman Ogee profile, and then machined a series of rebates and shoulders over the table saw.
|Laying the foundations for the moulding planes.|
|The Half Round Plane cuts the nice rising curve against the vertical shoulder.|
|Using the No78 Rebate Plane to complete a shoulder.|
|The Blockplane creates s chamfer ready to create an Ovolo.|
|Using the right radius Hollow Plane to create the Ovolo with a quirk on each side.|
|Progress check thus far... looking good!|
|Rebate cut along the lower LH edge ready for the next profile.|
|Combination of Hollow and Round to shape the lower Ogee.|
Fitting the mouldings to the front side of the door.
|Done. Rough enough, eh?|
|Front side: new lower mouldings fitted. Now laying out the old top mouldings.|
|Gluing down the mouldings to the shaped marine ply panel.|
|The missing centre piece replaced, and a glue/sawdust mix used to fill small holes around the arch.|
|Discrete scarf joints join various good sections together to create the long top sections.|
|Checking all the pieces before gluing and nailing in place.|
|Top mouldings fitted and complete on the front side of the door.|
Opening flush with the inside edges of the bolection moulding.
With the front side complete, it was time to turn the door over and contemplate the other side.
|Back side of the door, without mouldings.|
I learned years ago that old bed frames are a fantastic source of nice close-grained Oregon. I just happened to have the side rails from an ancient bed frame in my timber rack.
|The old bed would be recycled to create the new bolection moulds for the back of the door.|
|Machining up the material from the bed frames.|
|Here we go again!! Foundations laid...|
|The back of the door looks as good as the front.|
|Turning the profile on the curved top mouldings.|
|Matching the profile with a profile gauge, section by section.|
|One of the two halves. Looking good.|
|A pretty good fit!|
A 7mm deep x 12mm wide rebate was cut in the back to the marine ply panels to house the leadlights. This meant the leadlights would be housed between the two bolection moulds. Hence the back side mouldings would be screwed on, enabling temporary ply panels to be fitted awaiting the leadlight windows, which had yet to be made.
|Curved mouldings temporarily screwed on. Now the straight sections would be screwed on.|
|First undercoat painted on. Looking good.|
The door was then hung, and new lock fitted with much of the old hardware cleaned up and either re-fitted or awaiting the final completion of the door - leadlights, paintjob, etc.
|The undercoated door, mostly revitalised, modified, and now hung.|
Bring on the leadlight panels!
It's been a priviledge to give new life to this lovely old door. Making the mouldings and integrating this into the modification allowing the insertion of leadlight panels was a challenge and a delight. Along the way I often fell like I had met the tradesmen who originally made this door over a century ago. As I carefully pulled the door apart, the tool marks they left behind gave me an insight into their approach and thus their personalities and skills. Now I have left my marks on the door too.
Maybe in another century another tradesperson will be giving this same door new life again... who knows? However I bet they'll never know the material from an old bedframe is now integral to this door! I love the fact that unless it rots or is eaten by insects, wood can be recycled indefinitely. For millenia. Fantastic, eh? This door is living proof of this reality, and stands in stark contrast to our current wasteful throwaway Western culture.
As I worked on this door, I'm sure I could feel the planet smiling...