Replies

1. 
   YesMaam27577 | Nov 03, 2009 04:06pm | #1

   There are a number of things to think about when making exterior doors. Probably the most important among them is the contruction plan, and the placement on the house.

   Placement on the house (which I know you can't control) is important because any wood door needs to be protected with an overhanging roof. This reduces the effects of direct rain, and of direct sun. Both of those can kill a wooden door in a few years if its not protected.

   Construction for anything that wide needs to use either frame-and-panel design, or it needs to be done with a built-up slab (which may or may not be veneered). The classic exterior door is frame-and-panel.

   And for frame and panel construction of doors, you need to use very deep mortise and tenon joinery. (Very deep, in this case, means through mortises, or almost-through. The larger joints add the strength that is needed due to the oblique nature of the force of gravity -- doors are only supported from one side.

   If you plan to paint the door, wood species is less important than the paint. Use an oil-based primer for all 6 sides/edges; and use at least two coats of topcoat.

   For a stain and varnish finish, use a good quality stain, and allow it to dry for a couple of days. Then coat the door with a weather-resistant exterior grade varnish. Marine Spar varnish comes to mind, but there are others.

   And when you're done, post a pic.

   I won't be laughing at the lies when I'm gone,
   And I can't question how or when or why when I'm gone;
   I can't live proud enough to die when I'm gone,
   So I guess I'll have to do it while I'm here. (Phil Ochs)

2. 
   doorboy | Nov 03, 2009 07:48pm | #2

   White oak from right there in the Appalachians is as good a choice as any. For stability, quarter sawn or rift cut would be your best bet.
   As with any exterior wood product--seal it properly and maintain that finish through the years and it will outlast any of us.