digest
Short Summary
Main recommendation: Build a redwood doormat from a single 8-foot 2x6 board, held together with steel rods, plain washer spacers, and eight screws, then finish it with a single coat of transparent deck stain. The total cost is about $24, and the speaker says it took a couple of hours to make, compared with doormats he has seen sell for around $200 online.
Key Points
- The mat is built from slats cut from one 2x6 redwood board chosen for having the fewest knots.
- Two 3/16-inch steel rods run through drilled holes to hold the slats together, with washers acting as spacers.
- A simple frame with 45-degree mitered corners and rabbets (grooves) supports the mat and is joined with a Kreg pocket hole jig.
- Rough, unsanded finishing is intentional so the mat does not become slippery.
Details Worth Noting
- Concrete instructions:
- Materials: one 8-foot 2x6 redwood board, two 3/16-inch steel rods, about 30 flat washers (1/8 inch thick) used as spacers, from the plumbing department, and eight screws. Total cost cited: $24.
- Cut six 3/4-inch-wide strips from a 44-inch-long piece of the board. Cut three slats from each strip, giving 14 good slats with four spares. Cut the slats oversized, about 14.5 inches long, and mark the best side as the top.
- Drill 3/16-inch holes about 2.5 inches from one end for the first rod, and mark each board with an X on one side so they stay in the right orientation. For the second rod, set a stop block 11.5 inches from the bit, since the boards are different lengths. Round over the top edges for a decorative touch.
- Thread the rods through, pushing the boards tightly together, then square the mat by running one edge through a table saw.
- Reassemble with plastic washer spacers between each board, leaving an 8-inch gap for the frame. Trim the rods to about one inch on each side and cap them with nuts if using the mat without a frame.
- Frame: rip the remaining board lengthwise into 2.5-inch-wide pieces, cut a 3/8-inch-wide, 3/4-inch-high rabbet on a table saw dado stack, make 45-degree miters, and drill 1/4-inch holes so the rods fit with some play.
- Trim the miters gradually until the frame fits, then join corners with a Kreg pocket hole jig and eight screws.
- Finish with one coat of transparent deck stain, applied generously to all surfaces including the underside, and let it dry for 24 hours. Wiping is not required.
- Sanding should be minimal to keep the surface rough and less slippery.
- The speaker notes the mat could be used without the frame.
Bottom Line
A sturdy, low-cost redwood doormat is achievable with basic woodworking tools, careful layout, and one coat of deck stain for finishing.
