SNOW DAY across the Island!

Ok, coffee is over I guess. Back to work. Doors are well on their way. I didn't have much to go off of plans wise so I made one up based on all I've read and learned so far. These will set up overnight and I can fill holes and sand them up to be ready for primer tomorrow. I might gel stain them but that will be months from now.

They are 24" doors modelled after the doors in our living room my wife likes. They ended up being 2 3/4" thick and I estimate the weight at around 120lbs once the glass is in. Pretty standard issue except where the window casing is concerned.

The windows will set into a frame pretty much as the finishes go into the room. You might notice there are holes drilled into the casing at the corners and near midpoints on the sides. These are to reduce resonance between the glass as the interior panel is vibrated by the room sound. The ports open to an insulated cavity around the window where the goal is to have the energy decay harmlessly. The gap between the glass will be wrapped with fabric so no one is the wiser. The windows will be sandwiched between neoprene gaskets and held in place by trim on the face of the door panel. Dress them up later with some sort of recessed panel look.

Instead of drilling the door out for a lockset I'll attach cast iron handles to the door face. The door will pull closed and be retained by bullet closers (2 per door top and bottom.) Never heard of them before this, but really cool find. Basically a spring loaded ball bearing that goes into a stationary strike on the threshold and top jamb.

As you have guessed by now I'm kinda going OCD with all this stuff as best as I can for as little $ as possible. These cost 450$ all in. No way I could have had these cash and carry. "Soundproof" french doors don't exist to purchase off the rack. All quotes were for custom doors and were too spendy 1K plus for only single pane glass. These have 2 panes of 1/4" laminated per door. Almost bulletproof for Chess! laugh

Anyway, pic time.

The door framing.


Window assembly


Door insulated


Doors assembled up

Last edited by Serenity_Now; 01/28/15 08:25 PM.