Greene & Greene Inspired Entry Door

Brian Benham

Brian will show you how to build a Greene and Greene inspired entry door, which can also be configured as an interior door. The door is made using stave core construction which helps with stability and prevents warping. We'll cover all aspects of construction as well as the mortising for the lock set and hinges as well as hanging. Details abound in this one of a kind build. Your house will thank you!

  • 11 lessons
  • 192 min
  • $79.00

Here's what we'll cover:

  1. Intro & Door Panels

    It is always a good idea to measure your wall thickness to determine your door jamb width and to verify your rough opening before starting your door construction so you can make any adjustments as needed. There are some standards. For example, 2×4 framed walls with drywall will require a 4 9/16” jamb width, 2×6 […]

  2. Stave Core Rails & Stiles

    This type of door construction is called a stave door.  The strips of wood help prevent the door from warping or cupping and reduce the amount of wood movent, helping prevent the chance of the door sticking from high humidity.  The staves are made of Sapele, a lightweight rot-resistant wood, and I chose Cherry for […]

  3. Joinery

    Whenever I cut a groove down the center of a board, I always run it through, then flip it around and run it through again.  This guarantees that is will be centered on the board. Key Takeaways I typically mill up an extra piece so I can do test cuts to dial in the fit […]

  4. Cloud Lift Rail

    This is a pretty straightforward video on pattern routing. Key Takeaways I use my shop-made I-beam caul clamped to the workbench as something to push against when lining up my template.  It helps a lot to keep things from moving around. To reduce tear-out I cut most of the waste away at the bandsaw To […]

  5. Test Fitting and the Center Stile

    I built in a little fudge factor in when doing the layout; so after the door is assembled, I can cut a little off the top and bottom, cleaning up those edges and also allowing us to make sure the center stile, rail, panes, and light dividers are tight top and bottom.  This is why […]

  6. Decorative Cloudlifts & Divider Lights

    Using grain direction is a huge part of my workflow, not only from a design standpoint but from a construction standpoint.  I always try to use the grain to accent my design whenever possible and then use it to help make a stable piece, as I did at the beginning of the project with tight […]

  7. Finishing

    You will want to use an exterior-grade finish, and there are many options out there. However, the best finish to use is the one you are comfortable using. Key Takeaways: Prefinish the panel before installing it into the door frame so wood movement won’t uncover an unfinished edge. Be sure to finish the edges of […]

  8. Door Assembly

    When assembling something with this many parts, I like to use a slow-set epoxy, so I have plenty of time to get everything adjusted properly.  Every joint is tight, and the door is square. The panels are prefinished with the moisture barrier, sealer coat, and 1st coat of finish, so if there is any wood […]

  9. Door Jamb

    When building your door jamb, be sure to verify your wall thickness to determine your door jamb width. There are some standards. For example, 2×4 framed walls with drywall will require a 4 9/16” jamb width, 2×6 framing will need a 6 9/16” jamb width. However, many things will change these standards, such as using […]

  10. Hinges, Hardware & Final Finish

    There are a lot of different types of hinges and door locksets out there; one thing to pay attention to when selecting your lock set is the “Back Set”.  Back Set is how far back from the edge of your door the lock will be bored. Key Takeaways The most common Back Set is 2 […]

  11. Door Install

    Be sure to install your door on a 14-degree Farinhite day with a fresh coat of snow on the ground 😉 Key Takeaways I used Zip System stretch tape to create a sill pan to prevent water from coming in under the door You can buy a premade sill pan, but I have found Zip […]

What will I receive?

  • Detailed cut list and plans including a PDF and a SketchUp file (Metric and Imperial) for 30″, 32″, and 36″ Doors.
  • Video instruction showing every step of the build.
  • All videos and plans are digital and will be available for download upon purchase.

What will I learn?

  • Stave door construction
  • Floating tenon joinery
  • Resaw and veneering
  • Laying out a grid
  • Hinge and door lock installation
  • Door installation
  • HVLP applied exterior-grade finishing system

What will I need?

Rough Material List

  • 1 sheet 3/4” MDO exterior Plywood
  • 2 BF 4/4 Figured Maple for top Lights grid
  • 21 BF 5/4 Walnut
  • 15 BF 8/4 Cherry
  • 26 BF 4/4 Cherry
  • 24 BF 4/4 Sepele for staves


Table Saw, Bandsaw, Jointer, Planer, Router, and Sander


The instruction was great and the editing video was very good. Doors are posted on TWW guild under a Greene and Greene inspired door. Thanks

william bissell
Guild Member
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About Your Instructor:

Brian began his career in the trades when he was 13; he took an entry-level position working in a steel fabrication shop for a bridge construction company.  Being the kid in the shop, the old grizzled welders took pride in teaching him how to weld, set up his work area to be safe and productive, build jigs for production, and how to properly lay out a workpiece from shop drawings.

In his mid 20’s, he worked as a project manager for a design remodel company designing and remodeling spaces for commercial and residential clients. The company had an in-house cabinet shop so they could design and build from the ground up anything they needed for a project. When Brian wasn’t on a job site, you could find him in the cabinet shop, working alongside a shop master, creating custom cabinets and built-ins.

All these years of designing and building things honed his skills to give him the confidence he needed to start his own business.  In 2010 Brian started his design-build firm, Benham Design Concepts, specializing in designing and building custom furniture. His drive to learn new things has helped his portfolio grow and attract clients who are looking for the unusual.

Brian has been making plans for the Wood Whisperer and the Wood Whisperer Guild for several years now and often provides consultation on TWW and Guild designs.

His Instagram and Youtube handle is @benham_design