Hey everyone it's Dylan and Charlie from The Black Forest Wood Company
this week we have another door video for you guys and this one's going to have the full process
from the beginning of construction to the final installation of the door in the client's house so
it is a solid maple arch top door that we stain this really nice rich dark brown color
the client loved it we put a lot of effort into this door so it would really mean a lot to us if
you guys could leave a comment subscribe and or like the video all of that really helps us out
and let's get into it let's see this door so when we're creating our jams for our arch top
doors we actually have to create a cnc template to get the perfect radius that we need and then
we just screw in all of these blocks into our work table we'll line the inside with tuck tape
and then we use our three millimeter solid wood plies and tight bond three and glue them up in a
stack lamination to get that arch top that we're going for so we put all the glue on and then we
honestly just put a whole bunch of clamps until it sucks it tight to that form and with titebond
3 you do want to leave things in the clamps for at least 24 hours and sometimes on these arch tops
we'll leave them in a little bit longer just so they can set and hold their shape oftentimes with
an arch top it can be four to five days that it's in the clamps the rest of our jam components are
also constructed from solid wood so everything on this door is solid maple and you'll notice that we
actually screw all of the components for our jam together so we're using four inch number 12 screws
and we're usually using like three or four of them on almost every corner a lot of people comment and
say that it would be better to use glue but we've been doing them this way for quite some
time well my dad has been for over 25 years and we've never had issues with any of our frames
when it comes to finishing our doors we like to use oil-based products because we find they're a
lot easier to keep looking new without expensive maintenance in the past we have used sprayed
polyurethane finishes which look great and protect great initially but over the years they can begin
to flake and peel which results in the door having to be stripped causing a pretty expensive repair
so this door we're using the osmo stain and the osmo uv oil which you guys can find on our website
and that's currently what we're using on all of our doors we've got a beautiful uh curved
maple door here that we're doing solid maple stained it's going with this jam here
it's got double side lights and a little transom up top um it's all ready to go it's fully finished
so we're just waiting to install but it's good to go it's large it's real large
barely touch it's pretty big door i think it's nine feet tall we had to make this one
little spot right here to flip it because the rest of the ceiling isn't high enough
after all the components are finished we can put the glass in so we're just using two-sided
self-adhesive tape here and we also like to put a little bit of silicone in the corners just to
make sure we get a perfect seal and we lay that glass into place and then there's just solid maple
mouldings that we nail in around the perimeter to hold all those pieces of glass inside the door
the nice thing about just using the mouldings on the outside obviously
is that you can pop them off and replace the glass quite easily if you ever needed to
they call me the David Blaine of my generation
uh just the people the ones that matter you know them those the ones that have the ability to say
I don't make the rules I just play by them
and then after everything's assembled it's always important just to do a test fit
one more time after the finish has went on before we go on site we do the same thing
before we finish the door but we like to do it one more time with all the hardware in all the
finish on just to make sure that we're not going to run into any problems when we do get on site
so brad actually came on site uh the day before and did a lot of the dirty work on this job they
had to take a grinder and cut out the extruded aluminum frame which you can see was kind of
sealed in by some of the bricks so very messy very dirty long job but they got it done and here you
can see the team is pulling the frame out getting ready to put our new frame in the rough opening
after we get the frame lifted into place we actually like to leverage it up and
put some shims underneath so that's just the blocks you see us sliding underneath right now
there's two reasons we do that number one it will push the top of the jamb
tight to the radius at the top and make for a nice fit and then it also gives us a gap underneath
to be able to insulate and create a thermal barrier underneath the threshold of the door
disruptions
oh they call me the plugs
and then as a final touch on the interior of the house, we did matching casing
that actually ties in with perfectly with the stain of the door so that's what you
see spencer and electric marking out and cutting right now so we've got the piece
that goes across the top then the two pieces down the side and that just kind of helps to
tie everything nicely and together and hide all that ugly spray foam insulation that's in there
installing good it's very hot but it was a good install I think we did a fantastic job the old
one was kind of nice though too right the old metal-clad and uh and fake wood door was really
quite nice but well I think we've improved it a little bit this is how you open and close
it like that
let's check and then i put that little security oh perfect yeah good yeah all right
cool I think we're out of here okay well thanks so much great job guys so that was the entire
process of the door uh we will leave a few links in the description below for some of the different
things that we use like the tight bond uh the Osmo exterior finish we'll leave a link for that
charlie's ready to get on with his day but
I appreciate if you guys have watched all the way until the end of the video
last week we said start your comment with charlie and we would respond to all the comments and a
lot of you guys did that in response to that so this week start your comment with door and
we will respond to all of the comments that start with dor and make sure we get back to you guys so
thank you if you've watched all the way to the end of the video and we'll see you guys next week.