BeforeFinallySketchup modelCutlist Optimizer2x6x8' redwood lumber5/16" washers and 5/16" 48" rodCutting the redwood boards to rough lengthsSquaring one side of the boardsWith the squared side against the fence, ripping the slatsCreating the groove on the border sides with a dado stackGroove in the long border sideAll the slats cutAll the border pieces with the groovesStop block for drilling holes in slats at 10" from endStop block for drilling holes in slats at 20" from endCutting the rod to lengthTest assembly with washer spacers (2 washers = 1/8") - the washers can be seen, which I didn't wantSpray-painted the washers blackAnd now they can't be seenTest assembly of all slats by inserting both rods (without the washers)Trimming the slats to length. They ended up binding in the saw blade and I nearly had a serious kickbackSo I got smart and nailed a piece of scrap ply overhanging one sideRan the ply against the fence and avoided further mishapsFlipped the slats around, nailed the ply on the trimmed side and trimmed the opposite sideRounded over the edges on the router table with a 1/4" roundover bitMoved the fence back so I could round over the insides of the border piecesFinal assembly of rounded over slats with washer spacersMitering the corners of the border piecesDrilling two pocket-holes on each corner of the shorter border piecesWith a 1/8" spacer on the side, using a slat to mark the corresponding holes in the long border piecesDrilling holes with a depth gauge in he marked locationsFully assembled doormatAnother angleStress tested the doormat by jumping on it. It passedSanded the top down with 80 grit to ensure slats were largely smoothed out. Also that the mitered corner seams were flush. Don't need to use finer grit else it'll become too smooth and slipperyVacuumed the dust from sandingThe semi-transparent stain/sealer I usedGot it tinted redwood color at HDFully disassembled the doormat and stained (single coat) bottom, sides and end-grain of all piecesStained slats - all sides except topStained border frameRe-assembled the doormat after stainingStaining the top (single coat)Final productCoco approves
