Bonnet Frame Door — 2008

Material: Oak
Design & Build: Custom frame and door for existing opening

This project began with the need to replace an ill-fitting, cut-down door that had been used to block an existing opening. The goal was to create a proper, well-fitted oak frame and door that would both complement the building and improve weather protection.

From the outset, I had a vision of a frame with an integrated overhang — something to help shed water away from the top of the door and add a sense of detail and character to the facade. After some design exploration, I developed what I now call a “bonnet frame” — named for its resemblance to the shape of a bonnet, with a projecting head that forms a natural canopy.

The result is a sturdy, practical, and visually distinctive frame that enhances both function and appearance. While there may be a more technical term for this design, the name "bonnet frame" has stuck — and I think it suits it perfectly.

So back to my local saw mill. Another long chat with the owner and returning home with some very nice Oak off cuts. I wanted 75mm thick boards for the frame but all the miller had was 68mm , he was more then willing to rip some thicker stock down for me but the cost was ridiculous so i left with 68mm stock and smile on my face with some cash in my back pocket.

I just love this stage of the project  just me and a pile of sawn timber and a design in my head.

After ripping the oak boards down to size i squared up and marked the bevels on each section then cut to size. The mortise were cut on the router table to accommodate loose tenons.
This seemed the easiest solution for the mortise and tenons and i must admit it worked very well.

Gluing up

Gluing and cramping one of the frame sections.
I used a sash clamp to hold the two section together then a G clamp for the downward pressure. 

When they had dried, i ran them through the plainer to clean up the sides 

Next up was forming the curve of the bonnet frame. This i did on the router table and a jig.  

This was the longest straight router bit i had it's a little short but it will do.

Just above the spokeshaves handle is why i wanted the thicker stock.