Oak Door made from Old Scaffold Boards
2021 ж. 13 Мау.
3 116 312 Рет қаралды
The first job in our newly concreted workshop was to replace the rotten door. As per usual, we couldn't resist making it in oak... this proved to be a little problematic to get swinging but I think the result is worth it!
/ carlrogers
/ carlroge
www.carlrogers.co
Powered by:
Festool UK
Bessey Tools UK
Points for naming the 2 films in the NordVPN bit! Thanks to them for sponsoring this video and do go check them out at www.nordvpn.com/carlrogers or use the code carlrogers to get a 2-year plan with a huge discount and bonus gift!
As Good As It Gets? The other one I’m not sure. I know that’s not Clint Eastwood but Escape from Alcatraz?
Do you have the anti-kickback stops for your Festool saw? They mount right on the side and you'll never have that issue again on a plunge cut. Quality work. I've been watching your progress since the beginning.
The Bucket List (2007) and The Great Escape (1963)
Would it not be easier to empty the sawdust by taking the whole thing outside? Is ther a reason why you needed to dump it on the ground first?
The Great Escape, Richard Attenborough in the tunnel, seen Jack Nicholson but can't remember that one. Oh and that door is a thing of beauty, and now I'm off to watch the Great Escape.
I am an old-timer carpenter from Croatia. For my sense of beauty & design, that barn door is overstyled, although really well done with talent and skills. I used to work for a billionaire at his country estate at the Mediterranean. We bought 150 years old oak planks and beams for the doors. All imperfections were welcomed and appreciated! I treated the wood with hardwaxoil before I assembled the planks to a door, so even the no visible parts were protected against humidity. Note: the charme of an old building is his memory of centuries with its ups and downs, wars, wounds and different owners. Carl's new door will be best in 100 years.
Indeed. In one way the old door worked for me. The very wear and tear on it was a work of art. And it fitted into the old door frame like husband and wife. The key hole was magnificent. What would they have done in the past? I think a broad, thinner, old plank would have been attached over the bottom to cover the wear. If security is a problem then I would have no problem with fixing a high security lock through the door, leaving the old latch as original closure means.
Yes you do have a point, repair is always best than replace if at all possible. Was that old door salvageable?
I had the same thought: at least put some linseed oil on the planks before assembly.
I am an old Carpenter ,you are doing a great job.......But......I would like to see when you work around machines ...Take those dangerous loose jackets off .If they catch a spindle good night... Also tuck your white TShirt in under your belt ....Health and Safety. At all times..
With all those machines, who needs to be an expert.?
What about the Birkenstock security shoes ? 🙃
Great job...... should have done door frame.....next project in future. Love from Dublin Ireland X
Is it Own Molloy the metal worker??
Cut the cords off hoodies too, I nearly got decapitated when I was leaning over a car engine and the fan snatched it. that's a feeling that keeps me up at night
Please don't ever change the way you make videos and start jumping around playing pranks and cracking jokes . Perfect as they are thank you .
You just took shots at bourbon moth
@@saliyalokeshwara7055 The Kramer bit is just too much sometimes
Also no dumb unnecessary music
But he could bury the wind charms, how can you live with those?
@@johnleaper9711 But I really like the chimes!
As a joiner (for 36 yrs) and experience of making plenty of oak doors and gates, I've just got a few tips to make that door last a few years longer. 1. Leave expansion gaps between the boards. 2. Use stainless or brass fixings. The oak will rot steel screws quicker than you think. 3. Braces are too shallow. They should have gone bottom corner to centre of middle ledge and then centre of middle ledge to top corner in a line but at least you got them going the right way! Some so called joiners can't get that right. You might have been surfacing the best way as you sighted down the length but it did look like you were round side down on a couple of the boards? I was always taught to take a light few passes and push the board from the back, not press down over the cutter or you'll plane it bent. Also on the spindle moulder, when rebating I'd always have the cutter block at the bottom, that way if the board lifts you can run it through again. Your way it would have taken a big scallop out. Just tips, not trolling! 😊
much appreciated! really useful and well said so thanks for taking the time to write that :)
@@carlroge I'm sure there are other doors you can apply these advice on :D by the way thank you for restoring a piece of french history, the built looks quite premium so I guess it belonged to some local lord or whatever aristocrat family
i have to add a lil thing, on the plainer, you have to press it down, but on the 2nd half of the table, the half behind the cutter. Exactly how he did on the last few inch of the boards, thats how you have to do the whole board. Thats how to get a plain surface out of a bend board. And for that you have to lean over the cutter, so dont wear lose clothes, for safety ;) Also i hope there are no kids using this heavy door, since if it catches wind this can get quiet dangerous, we have used damper for such huge heavy doors (like at older cars trunk) to limit the speed of movement. Also nice work carlrogers. *Not my native language, hope it was understandable, cheers.
Good comments - the braces aren't doing anything once they are at more than a 45 degree angle - that's why for a wide door they don't go right across - if that makes sense :) and use the planner to take the majority of the 'thicknessing' process of the board - its quicker - once its down to nearly the correct thickness then pass it through the thicknesser
Completely agree on point 3. I've learned that "wood must stand on and steel must hang from the hinges". And indeed, one often sees wooden braces "hanging" instead of "standing".
After watching the video advert i was still skeptical. But when i finally downloaded the plans kzhead.infoUgkxZF0EMnrujZvqHhGkxiz559uIABJWR9TG i was very impressed. The whole plan was just as you said in the video. Thank you very much. I now have a large and valuable collection for my woodworks. This is great!
My late Dad who was a time served carpenter with a great deal of skill & ingenuity would have absolutely loved this channel. He never really discovered the joys of KZhead but he would have absolutely loved this and your other videos. Great work.
thats how i feel too about youtube.. of old songs..and videos my mom would have loved it ,, she often sang around the house . i know a lot of old song hearing from her singing and when i listened those song on you tube i cry thinking of her and how she would have loved to see and hear from youtube .
Did he also have a ton of money to spend on power tools but fail to use them correctly causing costly mistakes and only occasionally have to pull out the block plane and handsaw to bail him out when something requiring electricity couldn't be used all the while wearing birkenstock sandals and ear muffs for a pillar drill (??) and sponsored by Festool? Forget the "Norm Abram approach" with power tools. Angle yourself to a "Paul Sellers method".
@@mdr_random what happened to you friend? Are you ok?
That's an incredible tablesaw jointer planer set up. If you ever wanted to do a short video on that that would be very interesting. Or just mention it in a video somewhere. I live in the US and I would love to find some sort of unit like that. Great channel by the way man . Great work
Did you ever find out the name of that saw/jointer unit?
This young man is an artist among carpenters and builders. He takes his time and gets all the details right. (After many years working with heavy machinery, I do hate to see anyone working with a loose floppy shirt.)
I agree about his skill, and I especially agree about loose clothing around shop machinery. Loose sleeve near the belt sander was scary. I have seen what can happen, it ain't pretty. Also that young man using the drill press who was wearing that pink twirly thing around his wrist. Carpenter's apron helps, tucking in helps, sleeve covers help. Safety first. Great work!
@@rickcavtube Cheers, Rick. Glad we're on the same page.
I am fully impressed! It's just a complete kzhead.infoUgkxGqOCINHE0Z0E5gxzSdNi9NWGugRY5Hm2 plan with the best resources and step by step instructions . These shed plans are so satisfying as if the sheds build themselves on their own. Worthy work Ryan!
Holy Moly, I want that Table saw, router, plainer all in one machine.
Me too 😀
Does anyone know what the make and model is?
I found this: holzkraft minimax c26
Lurem also do similar models
That was less of a router and more of what’s called a shaper. Be prepared to drop $10,000
I have been a carpenter/cabinetmaker for 38 years. I always love learning something new. Watching a couple videos of yours now I have picked up a couple things to steal from you.
The before and afters do a splendid job of highlighting the quality of the finished new door. Beautiful!
What a remarkably well crafted door. I love how much care you all are putting in to the restoration and renovation of this farm. It will be going strong for another couple hundred years.
this is france and in that region there is a lot of humidity variation... there is make it look like and make it as it lasted so long.
@@jancloddlafront9185 And a little different perspective: Carl's great-great-greatgrandchildren might, MIGHT, have to think about replacing this door some day. Hope they are as skilled as Carl!
There wasn't a single thing about this video I didn't love. Your craftsmanship is fantastic, the editing is perfect and inserts of humour are on point.. new subscriber here and you've definitely inspired a few new ideas for my own channel. Good job 👌
Other than the fact that they don’t wear masks for the dust
@@stephencooper3480 this is true. I always try to put my mask on but do forget time to time.
Gee they should sell that saw dust to people who smoke meat fish etc
Lovely looking door and a bonus on the oak. Costs for oak are up 30% this year alone. Not sure if you did this but the vertical boards need to be spaced apart by a couple of mm. Essentially pull the T&G back apart before fixing on the ledges. If you don't do this your door is likely to bow around the ledge. The vertical boards pick up moisture and expand widthways, but the ledge will not expand lengthways with them. This forces the door to bow around the ledge to allow for the increased width of the verticals. Think bimetallic strip.
I read this twice to understand, thanks for the info. Also indirectly answered my question of glueing T&G.
I second Robert's comment. I've milled some reclaimed solid oak flooring for a small gate and needed to know these exact things before I proceeded. Thanks. :)
Just love seeing renovations using such beautiful solid oak. Great skills and patience.
Absolutely brilliant. I work for Stabila and we are actively encouraging young craftsmen and women through skills competitions. In a world of mass produced throw away products it’s amazing to see the skill, time and commitment required to build something as beautiful and durable as this door.
This guy is living on top of the hill of God. That aerial shot was so beautiful!
luberon...
Watching you work on these projects with great care and skill, reminds me of fond memories of my father. He would have loved your tools and techniques.
Very nice channel. You guys are enormously talented and rebuilding and restoring your farm durably probably better than the day it was build without loosing it’s traditional aspects. It’s all beautifully done.
The last component should be a drip ledge. To shed any water clear of the bottom of the door, so that it doesn't soak into the end grain, and cause rot, like the last door suffered from. .
The door sets under a roof and it doesn't appear he lives in a rain forest. lol
@@cletusspucklerstablejeaniu1059 LOL Rain gets wind blown, and water off the roof will also get wind blown, onto the door. That's why the original door was rotten. .
@@niklar55 ... Uh ... You do know this was a livestock barn ... A "300 year old livestock barn!"
@@cletusspucklerstablejeaniu1059 Naturally, I have two, also in France. Very similar.. So, I know the problems well. .
Always impressed by your attention to detail and careful planning. Little things like using some 3&1 oil on those hinge screws really shows your using your brain before you start building.
What's the purpose of the oil?
Yes, I love all the tiny details that help complete the 'job well done'.
@@micikas Makes it easier to drive them into the wood. 👍🏽
Goose fat would be more traditional, 👍😁
Vaseline (petroleum jelly) works well too.
Wow, what workmanship! That barn door is so strong & sturdy, it will likely outlive your entire family. It is so gorgeous, you can really be proud of your work! Nice to have your gf (or wife) helping you with the wood plugs.
I really enjoy ALL d clips u made from d Works around your Estate. Very professional. No stupid Talks, no terrible Musik, high Quality Videos,,, so nice to learn from.
The Quality of your work is outstanding in all that you do - from the carpentry, mill work and to the Videography and the planing well well done thank you
WOW…that’s a beautiful door, well done Carl!
I love how you rebuild your roof and now , a stunning solid door….greetings from Australia…..you are a true craftsman!
I just found you a week ago, and now I can't stop watching your content
Awesome, enjoyed watching this project all come together; thank you for taking the time to share it with us. Play safe from Elliot Lake Ontario Canada.
Dude! Sandals and socks 😬 I don’t know if I can watch any more 😂 - Awesome as always - Thanks
You should give it a chance. It's surprisingly comfortable.
Sandals and socks separate the sensible from the fashionable, and the shallow from the indifferent.
Beautiful recycling of that fine oak. I like the guide light on your chop-saw when cross-cutting the planks. What a fine work of art that oak workshop door is. Congratulations,
Thank you for the coasters arrived today , love the fact that you are recycling old wood.. The coasters will be part of a wedding present to my grandson and his wife. Thanks again...
Beautiful joinery there, Carl. It compliments your centuries' old barn renovations so well. Nice to hear the birds in the background too ... mourning dove, cuckoo etc. Very soothing. BTW glad to see you wearing stronger shoes to hang the new door. Seeing you in sandals handling heavy oak boards made me cross my fingers for your tootsies.
Well, I'm gobbstopped! Never, ever, have I seen someone with such skills and attention to detail on a project like building a barn door. It will still be hanging there when your great, great, great grandchildren run out to the barn to fetch something. Thank you so much for your videos. I so look forward to seeing the thumbnail on my feed.
Another wonderful video, excellent work! One issue, you have the door on the wrong way round!
The professional, who has made many mistakes, has learned many remedies. The remedies you show are very important. I remember all the mistakes I made, novel solutions are like gold.
Brilliant cinematography sound and editing......his carpentry skills are topnotch as well ! I could watch Carl Rogers build anything any day all day..... 😊😊😊😊
Beautiful work. I made similar doors with the same mould for the doors in my house, I used horse shoe nails to fix the rails and braces they turn out lovely but yours was perfection
Awe my goodness what a cracking handsome door! amazing team effort. Nice to watch real craftsmen at work. Thank you 👍
This was hypnotic. Good to see young people performing old crafts with such passion.
Makes me smile, a pleasure to watch and learn.
*Cool* Carl uploaded, Good to see you're back at the Farm. Place is going to be lit when finished, can't wait for the tour
thanks amigo, so tour scheduled for 2031? :)
WOW SUPER COOL PROJECT, I absolutely love watching you make items from scratch, I used to be an avid woodworker & really enjoyed it until I was diagnosed with MS (multiple sclerosis) 24 years ago, so now I cant work for more than 5 mins then my walking goes to pot. Anyways please keep doing what your doing & keep up the good work✌ PEACE✌
Watching you work brings back the memory smell of fresh cut oak. Its such a clean wood to work with and you have done the wood and yourself proud. Well done and thank you.
Carl if you have heavy or clay soil there, you can dig the sawdust in as an excellent soil conditioner. (This allows air into the soil for much healthier plant growth) 😊
depends on the species of the wood... some are great vegetation killers.
@@jancloddlafront9185 It's oak - and it's in the title. The risk - if you are really wanting to find fault with the idea - is of nitrogen-robbing by the sawdust with its large surface area as it rots down. But even this will be a short-lived effect as with tiny particle size it will break down relatively quickly, and the following year all will be well again, especially for nitrogen-fixing legumes. I manage an allotments site and use much sawdust in this way & in composting. I think Phil's idea is a good one.
@@jancloddlafront9185 like "eucalyptus" for example.
@@falfield I used to work in a cabinet door shop that just pumped it into a huge pile out back, 3-4 ft tall. Mostly oak and birch sawdust. That was about 10 or so years ago, and it's mostly still there. The shop has been closed at least 8 yrs. I would have thought it would have long ago been rotted. Only the part that touches the dirt is rotted a little more at a time. It was curious to me, is the reason I checked every year or 2. It's been about 2 years now. Time for me to check it again.
@@teenapittman4241 There are 2 reasons why it hasn't rotted, one a possibility and the other a certainty. The possibility is dryness - sawdust piles can often shed water very readily and be quite dry under the surface. Dryness is the reason the wood in your house doesn't rot. The certainty is the absence of nitrogen. Composting (an accelerated breakdown by natural mechanisms of organic matter, about which there's well-worked out theory & lots published) requires a balance of carbon-rich (woody/stemmy) material and nitrogen-rich (green leafy/sappy) material, together with air and water. Too much N and a slimy mess results (think a bag of grass clippings) and too much C and you get a dry, non-decomposing pile (your sawdust). Putting the sawdust direct into the ground causes the C to draw the N it needs to rot from the soil (so leaving less for plants to use for growth - the 'robbing' remark above). Were your sawdust pile to be mixed with sufficient grass clippings (much more than you'd think needed) or with fresh manure, it would make marvellous compost. In our food caddy (for kitchen vegetable waste, coffee-grounds and tea-leaves) we put a fistful of sawdust at the base. It soaks up moisture from the rotting tomatoes and similar and prevents it from sticking to the base so making for easier emptying. And this balances out a day's veg waste (2 vegetarians - several litres) and leads to a lovely rich wormy compost after being transferred to our bin outside and mixed in with garden waste.
Loving the socks and sandals of invincibility! 🤣😂
Fabulous project and outstanding craftsmanship, replacing a centuries old door with a beautiful oak replacement to last another few centuries. In our evolving world of environmental sustainability, truly a worthy project. Great video.
Absolutely first class woodworking skills, you must be really proud of that door, excellent video to watch.
Incredible workmanship, simply incredible and well done. I even like the inclusion of the mistakes.
I'm fascinated by your equipment! I was impressed when I saw the tablesaw doubled as a jointer, then again that it also functions as a thickness planer. I was sitting here thinking jokingly that all it needs is a router/shaper hidden in there somewhere and whaddyknow, it magically appears!
Lurem Optal 26
Beautiful build! I like the notched braces, I'm doing barn doors this winter and will definitely use that method. Very functional, and they look great, too.
Really splendid job! That's the kind of work I did and loved when I was your age back in the '70s. Wish I had had one of those combination table saw/planer/shapers, and those Festools! What fun!!
Incredible ...just Incredible. A door to last 100yrs
Marvelous, amazing how a simple door can become an heirloom . Wonderful craftsmanship and your design and execution was first rate.
The original door was much simpler and didn't take hours and hours using modern electrical tools to assemble. It probably took half a day or less to build the original.
Great to watch. My dad was a cabinet maker, working in the 1960s to 1980s. He would be astonished at the tools you have nowadays! Thanks for sharing.
Im from algeria and i really like what u did ...really nice job ..and I will bel glad to make u my teacher...thanks a lot
Wood is such a lovely medium to work with …. Love the wind chimes as well
That title drew me in.. Who would make Oak scaffold planks.?? And you told us in the first 30 seconds. Brill.
Great video. Cool door 👍👍👍
My favourite timber. Guess they are lucky guys from the sawmills mistake. They will have paid a fraction of the price for oak boards otherwise.
That door would stop a charging bull !!! Congratulations on your hard work and skills.
My new favorite channel. Truly Fascinating
Inspiring work Carl (and team) - always nice and easy to watch (nice pace).... nice to know I'm not the only one who makes mistakes
Another fantastic build, only this one out of bent, warped and crooked oak planks. It reminded me of wooden boat building with the methods you used. The door is more like fine furniture than a barn door, unbelievable craftsmanship! Thanks for the great episode
Thank you-- that was beautiful to watch. Gorgeous new door and faithful pooch🐶❤🐶
Amazing build. Watched the whole video from start to finish. The craft and detail that went into this door is truly fantastic. Great job Carl & co.
This took many hours of work to make a door. What a waste of time. Restoring the old door would take far fewer hours and it would organically fit in with the age of the building. Now there is a totally new door that clashes with the building's veneer of 'age'. The old door was not savaged by either sun nor rain, it being 'inside' the structure and not exterior.
Beautiful door! Amazing to watch the transformation!
What an awesome machine! Table saw, jointer and spindle moulder in one! Probably costs just as much as three separate machines, but only takes up the floor space of one 👍😁
Just found your channel, great job on the door and repurposing the planks. I like the combination table saw, jointer/ planner and shaper.
In the previous video, I was impressed by the polite work when I saw the re-roofing of the beams and roof. I am watching this video from Japan.
Good to see you do make mistakes and honest of you to reveal them too us all. Makes me feel a bit better about my own limited ability. Thanks for the inspiration. Keep on Rockin!
I really appreciate that you sand EVERYTHING to make it finished, professional, and pleasing to the eye. Master craft. I'm learning a lot for my own projects, even though they are not even close to your level. But in every effort I see an "ah-ha" moment. Also: Thanks for the Nord VPN coupon! I wanted it, because another VPN service was terrible, and just as I was looking to make the change you gave me a coupon and it's Black Friday. I saved a ton. Woo-woo!
I took a second cup of tea before i finished waching this great video where some other member of the family came and help. Great job.
Craftsmanship and skill, rare to see this anymore. Awesome job!
Awesome project, awesome video, work steps nicely explained. May God bless you for not covering your work with annoying music, like so many people insist on doing. Tool sounds are the best music to my ears. Liked. Subscribed. I’m in America. I recently bought a few tape measures and rulers in centimeters, converted my shop to metric, and boy, I should have done that sooner. The math is SO much easier. I beg all my fellow American woodworkers, to convert to metric. You’ll never go back. Finding half of 24 cm is so much easier, than some numbers like 3 and 5/16 ths inches. Or whatever. And millimeters are accurate. Anyway, Americans, convert, it takes one day to switch your mind.
The Festool track saws make an excellent jointer. I line up the track, rip a nice straight line and use it to reference in the table saw.
I’m very happy to know that I’m not the only woodworker who wears his Birkenstocks while woodworking 👏🏼👏🏼 No shame in the comfortability game!
The detailing on those woodwork projects is so so amazing 🙏🏼🪵🥰
This guy is simply a genius of detail, all things he created are unique
Absolutely beautiful wood and some great craftsmanship well done and made!
My first reaction: "WOW!!" Secondarily: That is a beautiful door. Thank you for sharing that journey with us.
Absolutely stunning door, yeah a few mishaps along the way but as they say, knowing how to do something is knowledge but actually doing it is wisdom, really awesome job, I absolutely love it, you and your dad are doing an amazing job with this place. really enjoy your channel and your skills. thank you for sharing
Great job! After being disappointed many times myself using the glue and sawdust filler, I would have glued in a sliver of wood to fill the saw cut. But it doesn't matter at all. Still looks great.
I was expecting that instead of the goo fixing method.
هو أنا قاعد فى وىشه
أنا عاوز أشوف اخبار
TgWags:::true that, Wags ! That is one of the older woodcraft methods and is called a “DUTCHMAN”….that is, a ‘spline’ of the same species AND grain pattern was glued in where there was a ‘resin canal’ or blemish or saw cut. These old guys also call the sawdust “FINES” and I think preferred a glue called “Flexwood Cement” to produce a same~species wood filler……..exp: Alton McCoy, Portland, Oregon….now McCoy Millwork.
It's been a year, feels like last week I was waiting for part two of the roof restoration.
What a beautiful door I watched every minute of it and loved it ,as I did with the roof, keep up your work its stunning whatever you both touch.
You are so patient I don’t think I could have been for a barn door build lol but that’s the difference between a craftsman like you and guys like me
I’d be sorely tempted to frame that door and hang it on the wall in the living room, spectacularly nice and your workmanship is superb!
I made my living restoring old buildings. The new door is inappropriate. I would have used the old door and simply build an inside face to it.
Indeed, repairing the old door isn't that complicated, one can easily scout out some old pieces of wood and insert this artfully into the lower left hand corner. There was no need to eliminate the old door entirely.
@@emsnewssupkis6453 👍
Perfection is a moving target
Barn door, boat-building level. Quite an overkill, for sure, but a pleasure watching (and making, I'm sure ;-). Thanks for sharing.
Brilliant to watch and good to see that craftsmanship like this still exists 👍🏻
Nice , I started my apprenticeship in 1964 and built many of these Bead & Butt doors in my day, retired now (71) but good to see people still have old style skills
I always excited for your vedios.your editing is very interesting.
thank you mate¬!
Thanks so much for attending me.
Whaaaaauwww this is absolutely next level woodworking and so nice to be able to see you creating this marvelous piece of art. Like this big time and it motivates as well in pursuing my own little projects. Love it 😊!! Thank you.
Will you reuse the old latches maybe? They look awesome.
When I first started watching your channel, I didn't expect this high level of excellency in craftsmanship. I am amazed how diligently you are working and how much attention to give to the smallest detail. I learned a lot just from watching your videos through the last days.
Beautiful craft! I also love your video editing, spare, no music , very few effects. Great voiceover narration. I treasure my little piece of 1732 oak. 😊
Excellent! Watched twice already!! I had high hopes that this workshop will produce many nice projects, and you delivered!! Keep up the great work!!
Looks great. I've never seen a combination table saw/planer. Seems like a cool tool.
A combination table saw/shaper/planer/jointer :)
You can see the love for work and for the house. Congratulations!!
Very nice work. My Dad always said that with the right tools and a little expertise one could move the world. Well, you have the right tools and more than a little skill. Kudos.
Door that will out live all of us! Cut the old door up and make something with it, like a toolbox for your router bits.
Definitely use that old door!
I'm loving your machine there. What else can it do? So far you have router, jointer (surfacer) planer (thicknesser) router and table saw all in one. I'm impressed
That's an awesome piece of work there, nice to see someone using skills like this. I always admire good woodwork, probably because I can only do it to a very basic level, that said I feel the need to take it further.