New front door
John in NM
I finally got to replacing our front door. I made several mistakes on the first one I built 15 year ago, at least I managed to learn from those and do better this time around. The material from the old door will make a much needed bench top too 


Most crucial mistake was in the exterior finish. I never wanted to believe that high quality exterior paint was the best choice for a west facing, exterior surface at nearly 7000' elevation. It is. Primer and 2 coats of premium paint on the outside, regular oil and Waterlox finish on the inside.
The mistake I couldn't easily fix is that it's an odd size - 42" x 84". I originally did that because I like a big opening for moving furniture and stuff. The extra 6" width helps, but it created a problem finding things like extruded sweeps and drip edges. Last time it never occurred to me to look for commercial 48" extrusions I could cut down - this time I found those easily (Zoro tool). So now I don't really call that a mistake 
The fun part was figuring out how to move it from the shop up to the house. The door weighs about 170 lbs (white oak). Luckily I had a cheap engine hoist for moving machinery and some discarded lifting straps from my last job, so it was easy to pick up from laying flat on saw horses for finishing. Then the trouble is to move it without a huge effort.
If only I had a really big hand truck...
Wheels are from a harbor freight hand truck - easily borrowed since the thing is so cheap that the axle is secured with cotter pins!
Just screwed my door stands down to the 2x4's and made a quick axle block for the wheels and I have a 10' hand truck.
With a plywood ramp it went in and out of the truck easily:
One nice thing about living in a hilly area is that most of the porches are right around tailgate height.
On the porch, ready to take off the dolly:
Once I got the dolly taken apart and the door sitting on the porch I got some help from a couple neighbors to actually fit and hang it. I can pick the thing up if its already standing, but going from the door stands to standing up is too much for me to handle the weight.