Back in December we unveiled our “finished” hallway project, but there were still a few loose ends to complete. Basically the only real construction left was to put a kickplate/edge at the top of the stairs and the thresholds in the doorways.
Being that I work at an ironworks, I got the idea to use some steel to take care of these pieces. At the top of the steps, I decided to use a piece of 1/8″ thick 2×2 angle iron. I had to use an angle grinder with a cutoff wheel attachment to cut out the notch where the 1/4 round trim is along the wall. I’m generally very comfortable with powertools, but let me tell you, an angle grinder with a cutoff wheel is a scary animal. I’m still working on the finish. Tonight I went to the shop and worked on it a bit, wire wheeling the surface and using a gun blue product to darken it, but i’m not 100% happy with the finish I got. Nonetheless, I came home and screwed it into place to see how it looks. I think it’ll work out just fine.

The edge piece in place. Note that notch work on the left hand side
Originally I had just planned to do some simple store bought thresholds for the doorways, but there were several problems:
1) My trip to Home Depot showed a pathetic amount of options and I wasn’t really into what I found.
2) I made some mistakes in how I cut the flooring in the doorways. For whatever reason, I didn’t make the hallway flooring go all the way to the inside of the door jamb, instead I cut it to only go midway into the jamb. Thus, when a door would be closed, it would leave about a 1.5″ gap that wouldn’t quite look right.
3) Leaving just the plywood as is would be problematic since it was just a normal pine plywood leaving an exposed edge would likely not handle traffic well, likely splintering and wearing down. Also, one of the doorways I cut very poorly and it was nowhere near straight or clean.
My solution was to get 1.5″x.5″ pieces of oak to abut to the edge of plywood flooring. I put a clear coat of polyurethane on these pieces to protect them, but otherwise left them their natural color. This provided a harder edge to the threshold that should wear better. However, this left a crack in between the flooring and this threshold trim. For this I decided to make some decorative steel straps to go overtop the crack.
For these I used 1/8″x2.5″ steel. Much like the stair edge, I wire wheeled these pieces and began to darken them using a gun blueing agent. Once again, I didn’t quite get the finish I was after, so there is still some work to do. Once I get the finish right, I will be putting these in place using decorative nails. I think this should provide a pretty interesting transition from the hallway flooring into the individual rooms.

Longview of one of the thresholds

Closeup of the threshold. Note the hole drilled for where the decorative nail will go

And this is the type of pyramid headed decorative nail that we’ll be using to secure the steel strips