A behind the scenes look at how the sketch on the left turned into the Bathroom Sliding Door on the right...custom designed, built and installed by the don j design crew!
After sketching and designing away, Joel (client and superstar) picked his favorite design and the building began!
Creating the large piece of wood that would eventually be cut into three panels started with wood glue and a crazy amount of clamps. It's like a torture chamber for glue and if done right, it works like a charm...aka...there were a few "trial runs". Note: The dino is Conrad, don j design mascot. He shows up every once in a while.
Three panels glued and one to go!
Ta dah!!! One piece made out of 4. Done and done! Now moving on to a beach load of sanding. To sand this piece to perfection, we used 6...yes, 6 different sandpaper grits. It went from, "Ouch! What up splinter" to "Smooth as a baby's bottom".
Then after all that gluing and sanding, we cut it up to make the panels. Making those cuts was nerve wracking...who wants to mess up, only to glue and sand all that wood together again? Not I! So at the table saw, I checked the measurements a solid 20 times and then with my heart beating out of my chest sent the wood panel straight into the saw blade. Phew! Luckily, checking my measurements 20 times helped, so it all worked out. And...then in don j design style, we torched the wood panels!
Now the real fun begins! We had to create something that no YouTube video would show us how to do. The three wood panels needed to sit between metal dividers...so we crafted a plan using flat steel panels to make inserts. A lot of strong spot welds and a few other welding details later, the wood panels finally had a home!
Welding shot! Also, the don j design theme song is the 1980's Break My Stride by Matthew Wilder. "Aint nothin' gonna break-ah my style...nobody gonna slow me down...oh no I got to keep on movin". Why? Well, in this biz a lot can go wrong but what goes wrong always produces a better idea. SO the chorus could not be more perfect! I found the most amazing video of this song and added it at the end of this blog. Check it out!
Assembly time! A big wipe to the forehead that the wood fits in its divider home. Home Sweet Home as they say.
The stain color is called Gun Stock. I picked this color because Joel has dark wood floors and an adjacent teal wall, so Gun Stock, with its subtle orange-ish undertone complements the teal and is beautiful against the dark wood floors. Locked and loaded (get it...because it's called Gun Stock)! Moving on!
Here they are...ready for their panel buddy, Mr. Acrylic.
Joel wanted a big pop of color so I knew I wanted to add acrylic as the 4th panel to help with this request. Honest alert...I had no idea what I was going to use, but just knew that something amazing would be found, and found it was. AND found it was! The stain glass window effect fueled Joel's color craze.
90 lbs of wood, steel, and acrylic later, the door is a complete! Dad and I are admiring the door and are excited to deliver the finished product.
This door is 87" tall, so old school Caravan to the rescue! Transportation...check! Thanks, Dad!
My husband and dad are ready for install. I told them to look tough because this door is going up a winding flight of stairs!
And it begins...
and up it goes...
Ta dah!!! You would think that was a close one, but dad and I took some serious stair measurements to make sure the 40"x87" door would go up that winding stair case and through the bedroom door.
Time for install! This is where I jumped back in to hang the trolley rail.
And finally the door is ready for its home. Thumbs up indeed!
With a few adjustments, the Bathroom Sliding Door custom project is complete! Now happy picture time with our amazing client, Joel!
And there you have it, folks. The first don j design Start 2 Finish Series. Keep scrolling for more finished product shots and the most epic music video/don j design theme song at the end. Also, sign up for my newsletter for updates on product launches and more Start 2 Finish Projects!