DesignBuildRestoreServicesAboutContactStart a project
A hand-carved egg-and-dart moulding run with carving chisels racked behind it.

A Hand-Carved Entry Door

Millwork · Hand Carving2024Russellville, Arkansas

Millwork · Hand Carving

A full reproduction entry door in new wood, with more than half the egg-and-dart moulding hand-carved to match the original, and a covered-over transom returned to service.

A large two-story house in the historic district, one of the older homes downtown. The original entry door had failed: mouldings rotted, the door sagging and leaking air. The replacement is a complete reproduction in new wood. Original egg-and-dart moulding was salvaged where sound, but more than half had to be re-carved by hand, the remainder being rotted or too brittle to remove in one piece.

A transom above the door had been covered over. It was uncovered, restored, and glazed with the house numbers. New historic-pattern hardware and latches, weatherstripping, and a new mahogany threshold. Painted and installed.

Windows & Doors
The completed entry door installed in its opening with glass and brass hardware.
Hung.
The restored transom above the door, glazed with the house numbers.
The transom, back in service.
The finished door painted black, with the carved moulding catching raking light.
Painted, the carving still reading.
A hand-carved egg-and-dart moulding run with carving chisels racked behind it.
Egg-and-dart, cut by hand.
Carving in progress on a moulding profile, with gouges and a pencil for scale.
One repeat at a time.
Detail of finished carved moulding profiles laid side by side.
Two profiles, matched.
Door stiles, rails and panels milled from pale hardwood and laid out on the shop floor.
Parts, milled and laid out.
Milled door parts showing cut mortises waiting for assembly.
Mortises cut.
A close view of a mortise-and-tenon door joint dry-fitted before glue-up.
The joint, dry.
A door in clamps during glue-up, a receding rank of orange bar clamps along the bench.
Glue-up.
Wide view of the door glue-up under clamps in the shop.
Clamped, and left alone.
The finished door laid flat, painted dark, with its hinges fitted.
Painted, hardware fitted.
The finished entry door standing on edge in the shop.
On edge.

Start a conversation

Tell us what you're thinking about building.

We take on a small number of projects at a time, which means we can talk properly about yours before anyone quotes a number.

Get in touch