Insulated Wine Cellar Door

[woodwerd]

This is a project I just recently shipped off to be installed.  Client is building a wine cellar and needed a custom door built.  Request was for a 3" thick door that had an R20 value.  Using Fusion360 I build all of the details and design for his approval.  It needed to have a double gasket design to ensure tight closure, and being 3" thick need 4 hinges (Hoppe adjustable) and a multipoint lock set.  All made from Solid Mahogany

Build took about 60 hours, built many test sections of each portion to ensure kerf gaskets would work as designed and all the mortised areas aligned.

I utilized almost every Festool product I own. Domino to join most sections, router to make the jigs that made the mortises etc.  Track saw to trim up finished glue up and on and on...  First project that I really saw the value of what I spent on my 4 month binge on Festool purchasing...

Still waiting to confirm a good install in NE, but everything was latching and sealing when it left.

Woodwerd
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make shift vacuum control

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full clamp up

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checking all the kerf alignments

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mortised auto plunging bottom seal asm

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hand hewn surface using festool planner

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surfix oil treatment

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clavos details added

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finish details

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in the crate...

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ready to ship..

 

[Dane]

Man, that is a sweet build.  Do you mind sharing your hardware specs and supplier?  I have been looking for a place to get a multipoint lock with no luck.  R-20 is better than my walls....

 

[woodwerd]

Ofcource not...

Did a bit of research to find everything that would work.  I determined that Hoppe seemed like the best quality for what I was trying to build.  Was most concern with clamping pressure for the double gasket system.  I contacted the local sales rep, who was very helpful to confirm all the details for the adjustable hinges and the multipoint options etc.

I used the Hoppe HLS One system 3 point pivot.  Purchased all of it online from allaboutdoors.com.  Took about 3 weeks to deliver but was nicely packed with no issue of bent rails / slides etc.

Adjustable hinges were worth every cent as they allow for a over 200 lbs door to be adjusted after install.. fingers crossed. 

Let me know if you want more details but if you go to:

http://www.us.hoppe.com/media/HLS-One-Tech05-15-13All.pdf

Has most of the specs and details you would want to know.  Also if you ended up using; contact the local sales for detail drawings of the mortise requirements.  I also purchased the Hoppe Euro router bit as it made the mortise pass exactly to the profile of the hardware in one smooth pass. Worth the ~$50.

WW

 

[Kev]

You certain that's going to be a wine cellar and not possibly a soundproof dungeon [eek]

Impressive build!

 

[woodwerd]

If the end of the world comes..  he will be ready for either scenario...  [blink]

 

[dltflt]

That is an awesome door.  Your customer will be very happy.

 

[b.hog]

Very nice , sir.

 

[Sparktrician]

Very nicely done!!!  I'm positively impressed.  [thumbs up]

 

[Dane]

Thanks so much for the hardware info.  I'm reinvigorated for building my own insulated door.  If you have any more nuggets of wisdom to pass along based on your experience, I'd sure love to hear it.

 

[Holmz]

That is impressive!

What is inside the door to get to R20?
Or does the wood get there on its own?
Seems like a good candidate for aerogel, but I am not exactly sure how.

 

[Ivanhoe]

Fantastic work! thanks for sharing -

 

[nclemmons]

Excellent!  Many thanks for sharing.

 

[woodwerd]

Re: Insulation value.. ended up closer to R12/R13.  Door is 3" thick, 3/4" layers front and back with 2 internal layers of Rmax Ridgid 3/4" R5 (R10 total), 1-1/2" Mahogany Frame. From all the research I did, no real way to get to R20 without added thickness.  Client agreed that R12 would be enough to maintain the levels he will need inside the cellar.

 

[tiralie]

Really nice work.
I particularly like the hand hewn work, your restraint (not too much) makes it look more authentic to my eye.
Tim

 

[bronco71]

How did you achieve he hand hewn look?  Did you use the HL 850 planer and if so which blade?  As stated it has just enough texture. Beautiful door!

 

[mike_aa]

Amazing looking door!  The choice of wood, color, hardware, and the hand hewn effect all add up to a first rate build.  I really like it and the finish is just right.

With regard to the construction, it appears that the hand hewn panels are glued up from solid boards and glued to the front and back.  Were you concerned at all about wood movement in these panels since they are oriented perpendicularly to rails on the underlying frame?

Thanks, Mike

 

[AlexThePalex]

Very good looking door, and nice to see the progress pictures so we get some insight in the work you've done to get there.

Are these types of doors a specialty of yours, considering the client chose to order from far instead of having it made locally?