A client contacted me to replace the arched entry door on their Tudor home. Besides just replacing the door, the client also wanted to add a lot more glass to the door to help brighten their foyer.

First step for me was making a template and laying out how all the new sections would go together.

Once I had laid out for all the parts, I made up secondary smaller templates for each section. These are then tacked to the white oak lumber I milled for the door and a router is used to get each piece to its final shape.

A quick test-fit to make sure everything comes together nicely before I attempt gluing it.

For the actual gluing-up of the door frame, I made up some plywood torsion boxes cut to fit the top arch. This allows me to clamp things together without worrying about the clamps sliding off the arched sections.

After the glue had dried, I removed the clamps and put the original template overtop of the door to make sure had lined up properly.

This door was a true divided-lite door, so here I am installing the center framework for the windows. The lower floating panel has already been painted the final color. Doing this ensures the panel never reveals any unpainted areas as it grows and shrinks with the change of seasons.

Inside each section I installed smaller T-shaped pieces that will hold the window panes slightly apart. Also at this stage I used epoxy to fill any minor cracks or natural defects in the wood.

Several coats of oil-based primer prepare the door for the final paint.

Before installing the window panes I painted the entire door the final color to make sure there would be no unpainted spots showing through between the panes.

Next up was installing the window panes and small retainer strips that hold them all in place. For this project I used 3/8” thick plexiglass panels because of the need for custom cutting the top angled panes. Plexiglass can be cut with standard woodworking tools, whereas glass can require more specialized tools and techniques.

I picked up a pair of these door dollies for the project. They allow you to stand the door upright and adjust it in all directions to aid in installation. They also make it a breeze to move a heavy door like this for transport.

The finished product, installed and fit to the existing doorway of the home.