I'm not sure if this is the right forum for this, but it seems close enough.
If not, someone move it.
These doors are rather special to me.
They were given to me by my mother 20 some years ago when she was remodeling a home.
I've tried to take care of them and they have been stored mostly indoors.
I'm currently building the second half of my home. ( a 20 year project so far)
There will be a wall with 3 doors, leading into the laundry room, a spare bedroom, and a bathroom.
I want to use these doors for those openings. The problem is, I only have two.
My plan is to take the current doors, which I believe may have been at one point used as pocket doors, and use them as single doors mounted on rails and pulleys barn door style.
These doors came from the Rancho Santa Fe area, and if I had to guess, Id bet they were 100 years old or better.
Looking as closely as I can, I'm willing to bet they were owned by numerous people over time, or may have been used in numerous configurations.
I might even go so far as to bet they came up used from Mexico.
It's quite obvious that there has been some renovations and repairs made as well, and quite possibly they were once kicked in.
One door has what looks like what used to maybe be a mail slot, that was later closed in.
My plan is to try and replicate a door to match. I believe it will be quite the undertaking.
For starters (and I may be wrong) my best guess is that they are constructed out of pine.
The wood is soft like pine, and may have been a premium grade because even though there are knots, there's not many.
The lumber must have been specially milled, or it came from a time when a 2x4 was really 2x4 or better, or maybe these started out as 3x5's or or 3x6 or who knows?
As they stand, the stiles are appx 4-4 1/2 inches wide or better. It's hard to tell because I believe they may have been resized to fit an opening and cut down a little.
The board thickness is every bit of 2 inches. Maybe closer to 2 1/4 or 2 1/2.
Of course I would like my replica to match as closely as possible.
There's a sawmill located about 150 miles from me that deals mostly with pine. I haven't talked with them yet, but maybe there's something they can do to accomodate the size of boards I'll need.
If not, I'll most likely have to use 2x6's.
Will it be obvious? Maybe, maybe not.
I'm still learning terminology, but I believe the building style is called cope and stick.
They've also incorporated a long through, shimmed mortise and tenon, that is also pinned with a crude dowell.
I only see what appears to be a few nails that were most likely placed well after they were constructed, and I see very little signs of glue, if any.
I originally looked at them and thought it could be possible to do everything on a table saw, setting up the saw multiple times for various angle cuts, dado's and tenons, applying a few different saw blades and a dado stack.
Months have passed since that first thought, and I have entered the world of routering, learning that there are bits that do most of those operations all at once.
I'm still in research mode, but I'm sure someone makes a bit that can cut a 1 1/2 inch cope and stick, or rail and stile.
I've also seen the bits that will create a tenon of any length desired.
Then there's the question of if there is such a bit available, will a 2 1/2 hp router be up to the task?
Is this more of a job for a shaper rather than a router, or should I go back to trying to do it all on the table saw?
Then there's the raised panels.
There's at least four (Tiers?) on the panels. I'm certain this can be done on a router in any number of ways, but I'm not sure yet which would be best.
I've seen bits that might just cut 3 levels at once, so maybe there's one that does 4?
I was just messing around the other night with a (very dry) scrap board and a straight 1/2" bit, and can see how it could be done, but it would take a whole lot of messing around and set ups. (pic below)
The spacers between the panels appear to be the same cut as the rails and stiles with 2 sides cut instead of one.
The shimmed tenons leave quite a bit of room for error which is nice.
Replicating the age and wear and tear is going to be a whole 'nuther animal.
So there you are.
I'm wide open for your ideas and suggestions.
I realize this will be quite the task, but it's a challenge that I want to undertake and accomplish.
I have taken some pics, and can easily provide more if needed.
Please note, one door is showing the front side, and the other the back.