​The original criteria for this commission were a large door with a full-round top, iron hardware, and, for privacy reasons, no windows.  After several discussions with the clients, we concluded that having at least some sort of peep-hole would be safer than having nothing at all.  The result was this mahogany entry door, complete with leaded glass speakeasy hatch.
 ​Arch detail.
 What's the secret password? Detail of the speakeasy "hatch." The leaded glass panel is shop-made.
 Speakesay hatch detail.  Slide bolt made by Bob Sanderson of  Sanderson Hardware .
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 ​I had never done leaded glass before.  Every project is an adventure.
 ​Every plank was handplaned planed and detailed before glueup.
 ​Four cross-beams run through the door for stability.  Wedged through tenons were actually the most practical way to join them to the outside rails.
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 ​Forged iron hardware.
 ​Interior detail.
 ​Each plank was resawn (or split down the middle) to have a series of cross-ways channels milled out of them.  The channels would then house cross-beams that ran transversely through the door, distributing the weight of each plank and stiffening the entire piece. (Please note the earlier picture of the the wedged through-tenon.)
 ​Dry-fitting tenons between the vertical planks and the lower rail.
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 ​Fitting up the arch.
 ​Why the router-ski-jump isn't an Olympic sport I'll never know.  Maybe the next time the Winter Games are held in Houston I'll bring it up with the committee.
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 ​Gluing in the frame that will eventually hold the "speakeasy" door.
 ​Building up the leaded glass panel.
 ​Test-fitting the speakeasy door before installation into the "actual" door.  It was interesting working on two completely different scales for this project: one that involved four strong men to move around the shop, the other that could sit neatly on the workbench.
 ​Wrapped up and ready for shipping.  I keep expecting Mr. Kubrick's apes to suddenly show up and start waving femur bones at this thing.
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