Front door - epilogue

As shown in my post from Sunday (10/4/09), more trim was required beneath the front door corbels. This post describes making and installing the additional trim.

It might be better to skim through this post, then read it again to understand these following details!

For additional trim, I cut 2-ft high pedestals, and a series of 1-inch wide strips to connect the pedestals to the corbels. The strips were 1-inch wide spaced 2-inches apart to match the relief on the corbels.

Wood board sizes are described in cross sectional area, so a 1x1 board is 1 inches square in cross section, and could be of any length. I wanted 1/2-inch by 1-inch pieces but could only find 1x1 at home depot. Below, I used a table saw to "rip" 1 x 1/2 inch strips from 1 x 1's. Ripping means to cut a board along its length. Using table saw, I ripped 1 x 1 boards in half to create 1 x 1/2 in. strips. It is done by feeding the 1 x 1 through the saw, sliding the board along an adjustable guide to get the desired thickness.

Then using miter saw, also called a chop saw, I cut an 8-ft 2x6 pressure-treated board (about $20 at home depot) into 2-ft boards, to make the pedestal. A chop saw is easier than table saw to cut boards crosswise.

It was a gorgeous day and setting up your power saws outside is helpful because you don't have to deal with sawdust.

Below, I cut angles at top of pedestal boards, using miter saw, for an angled look.

My door trim is a composite of layered wood strips and boards. This means moisture could get between the pieces. I painted all surfaces, including the inside surfaces that will not be seen, for protection and life. I painted all surfaces with Rustoleum oil-based black, figuring that will be a thick protective coating from mildew and moisture. Once installed, I used silicone caulking along the edges so water does not get between the pieces. The silicone caulking hardens like rubber.

Each pedestal consists of two 2x6 pieces. Below, you can see the first pedestal pieces. The second 2x6 pieces get nailed to the first, so the pedestals stick out more and complement the corbels. Below, I am getting ready to nail the 1/2 x 1-inch strips up to the 2x6 trim that runs the full height of the door.

Below, 1/2 x 1 strips partly in place. Up by the corbels, you can sort of see how I spaced the strips to match where the corbels flare out.

Below, I made 1/4 x 1 strips to go beneath the 1/2 x 1 strips, for further relief. This is because the corbels are so intricate that I think the rest of the trim must have some variety to complement.

Also below, you can see I've nailed the outer 2x6's to the pedestal.

The pedestal top is consists of two angle-cuts and two quarter-round molding pieces. It serves as a break between the strip lines above the pedestal and strips that I will put on the pedestal.

Below, two strips on the pedestal and blocks are used to create a recess on the pedestal, that is wider than the recess created by the strips above the pedestal. This is to give the pedestal a wider look, as it should since it is the foundation piece for the door.

I am pretty close to a color I like for the door, as you can see below. Note how Midnight Black and Gloss Black seem to go well together. Gloss Black is on the more intricate parts such as strips and pedestals, and Midnight Black is on the flatter, less interesting pieces.

ta da!