Custom Door Design and Fabrication : Residential - Commercial - Entry or Cabinetry

These custom chevron patterned vented doors were designed by Diana Johnson of Fifth Wall Design Group as a solution for residential vented HVAC mechanical room doors being a focal point of a residential basement build out in Charlottesville Virginia. She wanted a way for air movement without relying on conventional louvered doors. These doors where designed to have an array of CNC cut holes in the back core with a white oak overlay coving the holes from view while allowing air to pass through the spaces and behind the raised panels.

The doors were manufactured by us at PEV Labs. The core of the doors are cabinet grade pre-primed birch or maple plywood. The frames are Douglas Fir (Pseudotsuga menziesii) which are rabbeted to increase strength. The chevron pattern spacers are made from Douglas Fir, glued and fastened with a pin hole nailer. We made a pattern jig with the CNC which was used in laying out and securing the spacers. We locally sourced the rough sawn white oak from Black Forest Saw Mill a few miles down the road from us. The material was 4/4 so we were able to dress it up a bit, then get two re-saw passes with the bandsaw to bisect into 3/8 thick slices which we in turn ran though the thickness planer again to end up with about 5/16 veneering pieces to adhere to the chevron spacer pieces. We made a second jig on the CNC for oak since if overlaps the back spacers a half inch all around. That did not go as well as planed. We could see more variation in the spaces between the sections than we preferred. So once done we laid each door on the 4'x8' CNC and leaned up the cuts a bit. Also note we like a little Wabi Sabi so we choice to use material with a few pin holes, branch marks and color variation. Accented by the grey paint this all made for a very warm final product.

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Custom Doors Chevron Pattern
Custom Doors Chevron Pattern
Custom Door Patterned White Oak
Custom Door Patterned White Oak
Custom Doors Raised Pattern for Venting
Custom Doors Raised Pattern Venting
Applying Hardwood Pattern on Custom Doors
Applying Hardwood Pattern
White Oak Laminated on Pattern Backers
White Oak Laminated on Backers
Dry Fit Before Oak Lamination
Dry Fit Before Oak Lamination
Grey Paint Before Hardwood Lamination
Grey Before Hardwood Lamination
Porter Cable Helical Cutter Door Plane
Porter Cable Helical Cutter Door Plane
Morticing Door Hinges with Router
Morticing Door Hinges with Router
Door Frame with Chevron Pattern Spacers
Door Frame Chevron Pattern Spacers
Custom Door Framing Primed
Custom Door Framing Primed
Door Pair with Chevron Pattern Backers
Doors with Chevron Pattern Backers
Chevron Mirrored Pattern Doors
Chevron Mirrored Pattern Doors
Custom Door Frames Secured to Door Cores
Door Frames Secured to Door Cores
Custom Doors Plywood Core
Custom Doors Plywood Core
Rendering of Vented Door Design
Rendering of Vented Door Design