Small wood details on a door

My buddy asked me to look into his 10 light door. It was an old exterior door that had seen lots of weather. The small trim around a few of the lights had rotted and a couple of the panes were broken. Also, the vertical structure of the door was separating from the header and footer. While still connected, there was a lot of play in there.

Since the door is going to be part of an outdoor setup and it will be painted and set in a metal frame, keeping it original wasn’t a worry. The structures were clamped together and resin with glass filler was poured into the rather large voids to glue and stiffen the construction.

Replacement panes were a piece of cake. I found a place to cut them for me on the first try. On the other hand, the trim was impossible to find. I checked several hardware stores, lumber yards, and specialty wood shops without success. Finally, a custom cabinet manufacturer sent me off to the sash and door shop right here in town and they custom made the trim for me in about 20 minutes. It’s amazing to watch those guys work. They didn’t measure a thing. Using a table saw, router and a big sander they made 20 feet of the exact trim. Amazing. With any luck and a little bit of time the door will be painted, sealed and up in my friend’s garden in no time. The work is out of my hands now, so if you don’t see an update, it’s not my laziness at hand. Too bad I can’t say the same for everything else you see here.