I made a shelf out of an old door for the Spring boutique and I’m going to show you how I built it. And I’ll share some tips on finishing a piece that has old and new wood. Because we want them to look the same age right???
Tools needed: Table or skill saw, brad nailer, chop saw, drill
Supplies: 2x6, decorative moulding, door, 3 inch screws, wood glue, sand paper, and a drill
I guess I’m kind of skipping a step but this is a chunk of a 12 panel exterior door. **If you don’t have an old door lying around you can also use a 2x12 and do some simple picture frame moulding. It would be about the same effect.** Each row had 3 panels and we (I say we because this door was a heavy beast and I had to ask my husband for help) cut it into 4 pieces using my table saw. So I actually have/had 4 of these.
This door was 36 inches wide so I cut my 2x6 to 42 inches. Slather some glue on the top of your 2x6 then put it on top of the door, just make sure it is flush with the back and you have the same hanging over each edge. Then you can predrill some holes and attach them together.
I used a countersink bit so I could hide the screws later with some wood putty.
Here she is from the side. I put 5 screws along the top. You can do more or less depending on how you feel about it. If it feels wobbly stick a couple more in there.
Now that the basic structure is built, we can dress it up with a little moulding. Just cut it to size, check for fit, then glue and brad nail into place.
Now, it’s time for the worst part of any project, sanding. Oh how I hate this necessary step. Uh, if there was one thing I could skip this would be it. Is anyone else with me?
Since this door was pretty beat up…. I think it spent 2 Uintah Basin winters (translation-- freaking cold winter ) outside covered in snow, she had her fair share of slivers so I sanded the old door and the new wood.
Sometimes it’s super hard to get new wood and old wood to look good together. But I keep this mixture of apple cider vinegar and steel wool in a pickle jar in the paint cabinet just for these projects. It kind of gives the wood a naturally weathered look. It has kind of a grayish tint to it, like barnwood. You can also use this on the cut edges of a pallet or barnwood project you’re doing to make it look more natural.
***Disclaimer, don’t run and mix it right now and expect it to change the color of your wood immediately. The mixture has to sit in your jar for a couple days, even a week. Then give it a try.
Once you have painted your vinegar on, oh yeah it stinks bad!!!, I usually wipe it off with a damp paper towel and then you are ready for milk paint.
I used Miss Mustard Seed Ironstone. But you can use what ever brand you want. I just use MMS because there is a retailer close to me and I’m way too impatient to wait for paint to come in the mail.
On a project like this, where you are painting raw wood, you probably won’t get any chipping or crackling like milk paint is oh so famous for, but it still gives it a neat old look.
If you haven’t used milk paint, you might be getting nervous at the end of your first coat but just be patient….and a little brave. At the end of your second coat you will feel so much better.
After painting, I gave it a good distressing on the edges and in some random spots to give it a little more wear and then it’s done. Since I put the vinegar wash on it, when I sand the paint off the corners, it already has a dark finish showing. perfect! You can sand more or less it just depends on how much wear you want it to have.
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