08/06/2025
We were gifted a couple of solid core birch doors by a friend (Charles Piper). These were formerly used as barn doors for their architectural practice. I could not pass up the opportunity to take them and repurpose them.
I knew these doors were heavy but I had no idea how much! Each 36" door weighs 160 lbs.
Cutting into these doors and using them to build a project is not as easy as it might sound. The core is a mass of saw dust and glue and as you can imagine, does not lend itself to clean joints. I believed that there was a 1/8" thick layer of birch on the exterior but that is not exactly true. It's a very thin veneer laminated on a base of thick paper board.
Realizing that this was not going to be a perfect woodwork project as I was trying to force the material into a purpose not meant for it, I gave up any idea of perfection and proceeded.
I used the door to make the top and vertical pieces but then used a 3/4" plywood bottom to make it just a little lighter.
I am pleased how it came out. We located where it will be used as a bench, housing shoes, boots and routers under the seat.
After installing it, we realized that it will make a nice seating area for the grandkids with a folding table against it.