Replies

1. 
   gweisenburge | Sep 25, 2004 05:34pm | #1

   About two or three years ago I started a thread about a walnut slab entry door I hung on a house in Palo Alto, CA.  Could that be the one you're searching for? Although I can't find the thread, here's a link to my website photos of the door:  http://gwwoodworking.com/Architectural/Architectural.htm.

   I'm happy to report that the one-piece door looks great, remains flat, and swings effortlessly.

   Gary

   http://gwwoodworking.com/

1. 
   Indigo1557 | Oct 02, 2004 12:52am | #2

   Gary...thanks for posting...

   There were so many good thoughts in that thread....lots of doomsday comments about using a slab...lots of good construction comments etc.

   When it was all said and done, what did you find most helpful?

   I've just a got a commission to make a full slab table of claro walnut...its not the same as a door, but I wanted to try and understand the challenges of working with a slab.

   Kate

1. 
   gweisenburge | Oct 02, 2004 02:12am | #3

   Hi Kate,

   You know, I don't remember the discussions in that thread. I do remember posting in order to find someone with a similar experience using a slab. I don't remember my particular questions, but my concerns were related to wood movement - stability, of course.

   That slab had the heart of the tree, literally the pith, directly in the center of both the width and thickness. As with any such piece of wood, it already had a small amount of shakes and splits from the pith. I was worried about the stability of these "defects," although the slab had air dried for (I think) ten or more years. Actually, we all kind of liked the look of the tree's center, as well as the splits, in the middle of the door.

   I was concerned also that the piece might cup. For that reason, I originally proposed hiding a steel weldment in grooves in the top and bottom edges, believing they'd keep the door flat. Instead, I hung the door "bare," without added pieces of wood or metal - a one-piece door! Reserving future implacement of the weldments, I inspected the door for about a year until I was confident it'd remain flat. 

   I think the door remains flat and stable BECAUSE the pith is in the center of the slab. It doesn't expand and contract much over it's width, because the wood is nearly all quartersawn and therefore stable. I predicted wood movement over the door's width would be under 1/4-inch as a result of annual climate changes..... but it's been almost immeasurably small.

   I think it's been about three years now, and the door looks and works as good as the day I hung it. Imagine:  ten years ago I built a door of 287 pieces, and this one is of just 1 piece. I think that covers the possible spectrum.

   So have fun working with your walnut slab, but don't break your back moving it around.Gary

   http://gwwoodworking.com/