I must proclaim that we have the cutest, most adoorable door in all the land. Just look at it!
Drew’s dad Sam kindly put the door together for us. He used birch for the sides and pine for the paneling.
Drew and I ordered paint from ECOS because it was a non toxic exterior-grade paint. Unlike many other name brand paints, it lacks many of the heavy duty curing agents that make cause headaches, allergies, nausea, fatigue, and that infamous “wet paint” chemical smell. Ugh. We chose a barn-red color because we thought it’d go with the natural look of the cedar and would match our house well. We still may end up painting the exterior of our house because linseed oil isn’t a long-lasting solution, but if we do paint we’ll probably stick to a color close to what it is already – which goes well with the barn red.
After we painted one coat on the door we let it dry overnight. It was then time to work on installation! Drew worked with Sam on this. First, they measured the rough opening of the door, and installed a 1/2″ jamb around the top and sides. From there, they squared it up using shims to make the opening a consistent width all the way up and down. Inside, they mortised the door hinges into the door. Mortising is a technique used in door-making where the places where the hinges sit are actually cut into the door and door frame so they are flush. This part is super important to get right – everything needs to be square or the hinges will not work as smoothly. From there, they took the door outside and shimmed it up to just slightly above the height of the threshold and screwed the hinges in just to mark where they would sit. From that point on, it was a slow process of sanding and planing the door to just about 1/8th of an inch smaller than the door jamb on all sides. Once that was done and the door swung completely closed without any force, they took the door off the jamb and gave it a second coat of paint.
Doesn’t it look amazing? They did a great job.
Even though the door looks wonderful, we unfortunately have some issues with our beautifully small door.
For one, the window is slightly too large… Don’t worry, it fits just fine, but it makes installing a door knob and lock a bit more complicated. Here’s the deal: our window is so tall and wide that it actually makes the first available place to install a handle and lock very low. Lower than a standard door, for sure. Not only that, but we have a very limited amount of vertical space to install our hardware. We calculated that there is about 4 or 5 inches of vertical space to place both a deadbolt and a door handle. That is simply too little space for two large pieces of hardware that need big holes. We decided to keep a standard locking handle, but to look for something non standard for the deadbolt.
We discovered that over in jolly old England they make a kind of lock called a night latch, which is a kind of deadbolt lock that automatically locks behind you and can be opened with a key from the outside. The great part about these locks is that they are standardized which means they have many of the modern security functions of an American deadbolt like being bump, jimmy, and kick resistant. However, the best part is that they only require a 1″ hole, and the bulk of the hardware mounts on the interior surface of the door! This means it will take up less space than a standard deadbolt, and be just as safe.
Next we installed the door handle and lock, which took a while to arrive by mail. In the meantime, we had to use a plastic sheet to keep water from getting inside. (Ever tried to keep a door without a handle or anything to grab onto from opening in the wind? How do you keep it from opening on its own? It’s a weird problem.)
Because of the predicament mentioned earlier we ended up installing our deadbolt at the top of the door and the door handle in the middle. It’s still shorter than the average door handle.
Next, we needed to install weather stripping. This was a challenge. We’re trying to build this house as green as possible by sourcing as many plastic free, green materials that we can find, but as you can guess this is not easy. The majority of weather stripping we’ve found is either vinyl or PVC, both of which can leach toxic chemicals. Plus, the majority of them had Prop 65 warnings, which we also wanted to avoid. After hours of searching we finally came across rubber ones from Home Depot without a Prop 65 warning. Installing them was easy, as they just fit into the grooves (also called “kerfs”) on our doorstop. We needed to adjust our doorstop a few times for a secure fit, but in the end we had a tight weather seal all the way around the door.
Things will slow down from here as we begin on the plumbing and electrical. We have a large learning curve ahead of us, especially when searching for green plumbing materials…