Gnome Doors
Date Submitted: May 06, 2007
Turn an ordinary backyard tree into a magical one with a Gnome Door! Or, you may prefer to adorn your shelf of gnome collectibles. You can make this project in about an hour (not counting drying times) and no special woodworking skills are required although you must have access to certain tools. Base material costs average less than $3.00 per unit. They make wonderful gifts and are great sellers at craft fairs. Buying our complete set of Plans and Patterns will make this project easier and will offer 6 differnt door styles to choose from. Visit www.gnomedoors.net and get started on your own line of Gnome Doors!
Materials:
- One 2' X 10" board, cut to 10 inches in length.
- 1/4" BCX Plywood (this is sold in sheets and is sanded on one side and left rough on the other. You'll only need a small piece).
- 1/2" BCX Plywood. Again, you'll only need a small portion so there will be plenty left over for future projects.
- Dowel material: 1/4" and 1/2". These are sold in 3-foot lengths and average about $.40 each.
- Stain or Paint of your choosing.
- Waterproof woodworker's glue
- One sawtooth picture-hanging device
- Polyurethane
CREATING THE ARCH UNIT
1. Place the pattern for the Main Arch onto the best surface of the 2" X 10" board and trace completely around it. Cut it out using the scroll or band saw. SANDING THE OUTER RIM
2. Using a tabletop disc sander, sand just the outer rim of the Arch Unit until it is smooth. Run the bottom of the piece across the sanding disc as well. CUTTING THE INSIDE OF THE ARCH UNIT
3. Return to the saw and cut out the interior of the Arch Unit. Sand the portion that you have just cut with a medium grit sandpaper. Don't worry if it looks rough; this is a rustic project! CREATING THE BACKPIECE
4. Place the finished Arch Unit onto the rough side of the 1/4" BCX Plywood and trace around it. This is the backpiece. Cut it out with the saw. CREATING THE DOOR PIECE
5. Place the finished Arch unit onto the rough side of the 1/2" BCX Plywood and trace around the interior. Cut it out with the saw. This is the Door Piece. GLUING THE ARCH AND THE BACKPIECE
6. Apply waterproof woodworker's glue to the backside of the Arch Unit. Line the pieces up so that the Backpiece overhangs the arch evenly. (Remember: the smooth side is the rear of the project and the part that will show. The side that comes into contact with the glue and the Arch Unit is the rough side. Apply clamps evenly remembering to insert some protective wood pieces to avoid ugly clamp marks. Allow to dry. CREATING THE DOOR BOARDS
7. If you're using our patterns, select the style that you want and follow the instructions. If you choose a style of your own, cut the doorboards apart with the saw and sand the edges, beveling them a bit. This will add depth and dimension to the door front. Apply a dark stain (such as Driftwood) on the front and allow to dry. Once dry, sand it with an electric palm sander until most of the stain is gone. (Do not worry if it begins to look light. Once the polyurethane is applied, the stain that is left in the crevices will darken and evolve into a nice "aged" look). If you're adding detail such as doornails, bore out the holds with a 15/64" drill bit. Also bore out a hole for the doorknob using a 1/2 wood boring bit. SANDING THE ARCH UNIT FLUSH
8. Use the disc sander to sand the Arch Unit and the Backpiece flush with each other. Stain or paint the Arch Unit. Allow to dry. Cut the 1/4" dowel material into 1/2" lengths and tap them into the holes that you have created for the doornails. Apply glue to the backsides of each of the doorboards and lay them inside the Arch Unit. Apply a few clamps remembering to insert some protective wood pieces in between the clamps. GLUING THE DOOR BOARDS INTO PLACE
9. Cut the 1/4" dowel material into 1/2" lengths and tap them into the holes that you have created for the doornails. Apply glue to the backsides of each of the doorboards and lay them inside the Arch Unit. Apply a few clamps remembering to insert some protective wood pieces in between the clamps.
| 
