DIY: Pantry Door Tutorial

Due to the overwhelming response to the amazing door that Ric built for our kitchen pantry, I have asked him to give all of you a step by step tutorial.

He did not use a pattern or another tutorial just good ole' fashion handy man knowledge ;)

Please welcome my other half to the blog world...(applause!!)

Take it away babe:

Hi,
There was no exact science to the build.  It just evolved as I went...so I will do my best to give you a step by step "how to." Sorry for the lack of pictures, but I hammered it out while Sue was out on another "shopping trip". lol!   Lets start with the list of materials needed.

Materials List:

*All wood was cedar- I used 2x6's and 1x4's
*Gorilla wood glue
*Half inch dowel rods
*3 gate hinges
*1 door pull
*1 closet door ball catch for the latch
*Stain (Watco Danish Oil Dark Walnut Stain is the one we used)

Tools:

*Table saw
*Miter saw
*Planer
*Doweling jig
*Drill and spade bit
*Wood clamps- wide enough to clamp your door frame
*Finish Nailer
*Dremel

**I started by taking the original door off and used it as my guide for measurements-*Our door is a 24" interior door**

Step 1: Prepare all wood pieces for construction

*Plain all the 2x6 cedar down to 1 3/8" thickness (this is the thickness of an interior door)
*Cut 2 of them to 80" lengths (or whatever length the height of your door is)
*With the table saw I ripped the 80" length boards to 4 1/2" wide
*For the top, middle and bottom pieces I cut them to 14 3/4" length, these will stay at 5 1/2" wide (this is the frame of the door for a 24" wide interior door) 
*For the top, middle and bottom pieces- I used the table saw and cut a 3/4" notch on the back of the boards for the 1x4 slates to sit into...top piece only has one notch on the bottom, middle has a notch on the top and bottom, and the bottom piece has one notch on the top.
*Plain the 1x4 cedar down to 1/2" thickness (for the slats)
*With the table saw I ripped the 1/2" thick slat boards to fit into the frame.
*With the table saw I put the blade on abt a 45 degree angle and cut the sides to create the grooves between the slats
*For the X in the front- plain 1x4's down to 5/8" thickness


Step 2: Construction of door
Measurements of construction- our door is 80" tall, 23 3/4" wide...middle section of door is 33 1/4" from the bottom of the door

*Assemble the frame- with the doweling jig with a 1/2" drill bit
-Using the doweling jig and gorilla wood glue, I put 3 -1/2" dowels per side of the top, middle and bottom pieces connecting the 2 80" long cedar boards to create the frame of the door. 
-Clamp the frame together and let it dry (you can work on the door while it is drying)

*Assemble the slats
-Slats are already cut and ripped to fit- so just cut to length and fit them into the 3/4" notches on the back of the door (I cut a small 1/4" filler strip to nail the slats to the door...once you lay the slats in the frame you should have roughly a 1/4" gap)

*Assemble the X on the front
- Easiest way to cut your angles for the X is to lay a 1x4 across the bottom box of your door-line up the right side of the board with the top corner and line up the left side of the board with the bottom corner. Use a pencil to mark your angle on both edges of the board. (cut both boards the same) With the opposite 1x4 of the X, and make marks where it intersects the other board of the X.
-Using a miter saw line up your angles with your pencil marks and make your cuts
-Using a finish nailer- assemble your X

*Step 3: Sand and Stain- We used the Watco Dark Walnut Stain

*Step 4: Hardware
-I used the old hinges on the new door- and used the old door as a guide to trace the old hinge spots and used a dremel to cut them out.
-Attach your hinges and hang your door
-I then cut 3 gate hinges and matched them up to the existing door hinges for the barn door look
-For the door handle we used a garage door pull from Home Depot and inserted a closet door ball catch for the latch.

Total it took about 8hours from thinking it out to having it completed....and Sue still wasn't home from shopping yet...???  haa

Feel free to post any questions...like I said, sorry for the lack of pictures...I didn't know I would be doing a "DIY" tutorial.  If..(aka "when") I get suckered into doing another one I'll be more detailed. :)

Thanks-
Ric

Kitchen Renovation....Phase (I can't remember)

It was 8 months ago when we officially started the kitchen project.

                                           Before

After

 At first it was just a project to paint the cabinets,(post found here) but that was just the beginning. 

 The project grew and grew.  We added beadboard and corbels to the island (post found here)

                                           Before

After

Extended the fridge (post found here, and here)

Before

After

We lined the interior of the extension with cedar planks and filled it with some of my favorite things

(post about the meaning behind some of my favorite things found here)

And now on to the pantry!!

Before the door was just your standard builder grade white door.....and now its this...

Ric built the entire door from cedar and then stained it with our favorite stain

Watco Danish Oil Finish in Dark Walnut

Add a few hinges and a handle (this is actually a garage door handle that we purchased from...wait for it....HOME DEPOT  (are you shocked?) :)  

They say that paint is a decorators best friend, but Im telling ya, I think an accent door is number 2 on the list.  It totally transformed the look of the entire kitchen.

So, what is next for this "little" kitchen project of ours?? Well, here is what's on the list:

*Add chicken wire to the cabinets above the desk area

*Farmhouse faucet

*Copper apron sink

*Storage organization in pantry

*These barstools from Ballard Design (which are on back order until late August) but will be here soon!

With all this going on in the kitchen, we always seem to have a side project to keep things new and exciting. So, yesterday we ripped off all the carpet from the stairs.(blog post coming soon)  :) AHHH! I am beyond excited!!

Have any projects you are working on, just completed?? I'd love to hear about all your reno adventures!