exotic wood for an exterior door?

[Bill White]

As I live in the Tupelo, MS area, I know what weather we both share. Think twice before committing to a wood door. I have one now 'cause I have a very deep front porch. New home will face West and not have the large overhang. Steel will be in that puppy.
I finished the existing fir door with various stains, glazes, and 5 coats of a water based exterior poly with good results. Been up 1 1/2 years with no fading, checking, etc. Finished all edges the same way.
Bill

[Chris Allen]

Here's a pic of a mesquite front door. I like it.

[Greg Robbins]

Here's an article by Jim Kull who knows a lot about finishing that you may be interested in.

In a recent post my friend, Steve, made reference to my tests of doggie sprinkling on exterior finishes. I figure after almost a year of testing it is time to post some interesting discoveries.

As a preface, allow me to set the stage. Almost daily there is a posting about clear, exterior finishes for doors, chairs, signs and such. Responses run the gamut from diehard marine finishes to apply a coat of primer and then paint. Each of these has a bit of a problem. Marine finishes are not always the easiest to find and it grieves me to think of a lovely oak, teak, mahogany, fir, redwood or similar nice wood door painted in mauve goop.

Bob from Fl inspired me with his continuing and accurate statements about the failings of a clear coat and the advantages of a good quality exterior paint. I decided after lots of reflection that he really was right but there was always the picture of mauve in my mind. Sooooooooo, how could one take advantage of his advice and yet capitalize on the beauty of a nice wood.

I began to reflect on the characteristics of paint. Now, comes the boredom.

There were several things I knew about paint. Exterior paints contain a mildewcide and a fungicide that a varnish does not. The best quality paints will contain a UV protectorant and trans-oxide pigments in very high percentages. Almost all paint is custom mixed by the store. The retailer maintains a large supply of base products that are used to achieve the desired color. There are generally 4 base products and the specific one for your paint is determined by your color choice. These base products are either named or numbered. They are named pastel, deep, tint and neutral. If numbered it is cleverly 1, 2, 3 and 4 with the exception of Olympic who numbers 1, 2, 3 and 5. Olympic is unaware that 4 comes before 5. Pastel and/or 1 is virtually a pure white and used for the lightest of colors. The others are slightly color altered from white and more translucent than pastel. These are used for succeedingly deeper colors. All of this comes to neutral, 4 and/or 5. These are clear and used for the darkest colors. In the can they are somewhat opaque but dry more or less clear.

Now comes the testing. I bought 4 oak exterior doors. Each door was given one coat of the same MinWax Stain. On 3 of the doors, I applied 2 coats of "base" to the 6 sides of each door (3 coats on the top and bottom edges). Each of these three doors had a different type of exterior neutral, 4 or 5 base. The fourth door was finished with a consumer "spar" varnish from my local friendly paint/hardware store. The bases for the 3 painted doors were an exterior semi-gloss acrylic, an exterior semi-gloss oilbased polyurethane floor paint and a semi-gloss oilbased trim and siding paint.

The doors were set up, slightly inclined, in mostly direct sunlight under a pecan tree in the backyard. My wife just loved that one. Daily, the sprinklers managed to hit the doors. The birds in the pecan tree used the doors for target practice. And, yes, the dogs did anoint the doors on a regular basis. My blonde Cocker, Zazu, was particularly enamored with the doors. Over the course of the test the doors experienced lots of Texas sunlight, rain and snow. The temperature went from below freezing to over 100. The advantage to the inclined position of the doors was the snow, ice, water from the sprinklers and the rain tended to collect in the raised panel areas. I feel these doors were subjected to far more severe environmental conditions than would be expected from normal use.

The results were interesting. The "spar" varnish looked fabulous but after about 2 weeks it began to develop small cracks. In rapid order the door began to turn black, started to mold and the smell was enough to knock a buzzard off of a manure wagon. The waterbased acrylic is milky in the can like a waterbased poly. It dried to a more or less water clear surface but was a bit cloudy. It tended to wash out the stain a bit. Over time it became cloudier and ultimately become almost white. But, it remained solid and protected the wood. The oil based bases are also a bit opaque in the can but dried to a clear finish that is almost identical to a spar varnish - they added an amber tone to the doors. Both the oil based poly floor paint and the oil based trim and siding paint remained "clear" over the entire test period.

The testing came to an end with a bit of encouragement. My wife said something clever like, "Get those damned doors out of the backyard?". She does not understand science. The floor poly had some minor checking and a thinned coat of the same base over the surface made that disappear. The door with the oilbased trim and siding paint was perfect other than it had lost a bit of the gloss.

So, I am with Bob - paint the door. My preference is the oilbased products. If you are predisposed to a waterbased use an acrylic rather than latex.

One thing you will find when you go out shopping for your product is a lack of knowledge on the part of the salesperson. Not many of these folk are aware that their neutral or 4 base will dry clear. If you want to have some fun, spring it on them. They will suggest you are full of Donkey Dust. Ask them to shake a can and put some on a stir stick. Dry it and voila, it is clear.

Jim Kull

[Neal Clayton]

Sky is the limit on this one, Mark, I think. Jim mentioned the traditional/classical wood to use but typically, you want a very stable wood or one that is properly dried and stress-free so it doesn't move much on you. Properly finished and cared for over the years, it ought to serve you well.

Personally, I'd love to see a mesquite door!

I believe my own front door is made from vertical grain fir but after 15 years, the finish is coming off the bottom of it (not sure what finish it has) but overall, it still looks good.

chris beat me to it .

mesquite is too short a tree for many architectural details (there are not many, if any, 15 foot long mesquite boards from what i've seen), and even enough length for a door will be very pricey, but it looks fantastic. plus it's very weather resilient as others stated so a proper wood to use for such a thing.

[Jim O'Dell]

There was a thread a few years ago, IIRC it was here at the Creek, with a Mesquite entry way. I tried doing a search, but found nothing. I remember it being extraordinarily beautiful. Wish I could find it again. Jim.

[Chris Tsutsui]

FYI and gloat: When you pull off curves, then it makes it that much more unique.

These are door projects from several years ago. I have to give credit to my friend and former business partner on these. Sadly enough he quit contracting over a year ago due to the economy so you won't see his level of craftsmanship anywhere... instead, you'll see mine.

[Christopher Pine]

I took a class on door making at the local trade school, which has an excellent woodworking program and the instructor taught us how to make the core out of birch laminated together then a laminated layer on the outside of your wood of choice. I made one out of red oak and it worked very well. You use about 1/4 to 3/8 inch think exterior veneer and used a large vacuum bag in the glueing process. This makes a very stable door.
It is not finished as I have all the parts and just need to do the glue up and of course finish it.
good luck.

Chris