Manufacturing of interior doors with lighting.

Once I made a door for the doorway between the hallway and the living room with a pattern glowing in the dark. At first everything was fine, but there were several flaws at the door.
First, after the wood had dried, it bent slightly (I thought a “sandwich” made of glued wood would prevent it, but alas ... I was wrong ...)
In addition, there was only one layer of organic glass in it. The problem is that if the glass gets dirty, the dirt also begins to glow. This also applies to fingerprints. As luck would have it, both the guests and my family try to slap the glass ...
As a result, faced with these problems, I decided to make a new door.
This time I decided to take cheap boards, so that the door is straight and stable. In addition, I used four layers of glass - two external 3 mm thick polished glass and two internal 3 mm thick plexiglas, on which the design was engraved.I had to use plexiglass, because it conducts light better than ordinary glass.
These are four sheets of glass (bringing them home was not easy, but that's another story). By the way, they are green because they are covered with protective plastic.
This is the first piece of cheap wood, cut to the desired shape. Actually, nothing interesting - everything was sawing, sawing ... Besides, I had to use a milling machine to cut off all boards of 2 mm: I bought boards with a thickness of 22 mm, and the door thickness was 40 mm. Damn a lot of fuss. In addition, it was necessary to cut the grooves for glasses. I did not take this process, unfortunately, but on the other hand, there is nothing interesting in it.
All the boards have already been cut to the desired shape. In the two boards in the middle, moreover, the grooves are sawn through. As you can see, larger chips are used in the middle layer of cheap boards. I will discuss this in more detail later ...
This is the bottom of the door. Since the door is rather heavy, I was afraid that the usual wood screws could not stand, so I cut out small grooves between the two layers of wooden boards and pasted three nuts into them andM5 gaskets (A4 stainless steel - for sure). Below is a picture of the grooves for two 6 mm nuts and two threaded rods. They serve as a support for glass. Glass is fed through the lower part of the door (it would be easier on top, but this is impossible due to the large structural strength of the frame). Under the glass is a board and two threaded rods. Between them is also a piece of wood - to strengthen the structure and distribute the weight.
Snapshot nuts and gaskets for the loop close-up. The loop itself and the screws are already bolted to ensure that the nuts are glued in the right place.
Everything is glued and filled with filler.
A close-up shot of glass grooves. I had to use a filler to level the surface, because in the middle there is less board density. In addition, I neatly filed the edge with a milling machine. I hoped that the paint would be enough to fill all the irregularities and make the tree smooth ... alas, it did not work out. Here, I also had to use a filler (photos, again, no ...).
LEDs! To be exact - 120 pieces, 60 blue and 60 white.They will highlight the glass.
Holders for LEDs made from 3 mm thick plexiglas strips measuring 1 x 62 cm. I cut a hole for each LED and for each resistor (one resistor for three LEDs). In addition, I had to cut the groove for the cord. It will be located above and below the glass, under the weight of a single plexiglass sheet.
Lights up!
A close-up picture of strips with LEDs looks like an artistic photo. White seems bluish - I forgot to adjust the white balance on the camera ...
This is the first layer of glass with a pattern engraved on it (it will be blue).
... And the second layer (it will be white).
Both layers are connected to each other. The engraving is located on both sheets from different sides. Ideally, it would be great to engrave the drawing on both sheets from the same side, however, in this case the image would look perfectly at a right angle, but would divide when viewed at an angle (the figures would not coincide with each other by 3 mm).
Therefore, the sides on which the picture is cut,are facing each other. The problem is that with this the picture seems somewhat clearer on one side than on the other. However, as a result, everything was not as bad as I expected.
This is a very bad photograph of the first sample of LEDs. All four sheets of glass are laid on top of each other. The black edge, noticeable in the picture, is electrical tape, which serves as a gasket / seal.
By the way, this whole structure lies on the other door - not on the one I replace.
Here you can see how the light is distributed over the glass. Outer glass does not let light in at all, and plexiglass lets through two different colors. Light scatters much less than I expected. In fact, the blue color is much “cleaner”, just my camera could not fix the pure blue glow of the LEDs.
This is a ready-made" sandwich ". White film ensures that the glass will hold tightly in the wooden frame of the door.
Unfortunately, I was not able to completely clean the glass. If you look at an angle, dirt is noticeable on it. But this, fortunately, is not fatal. &Nbsp;
It turned out that the “sandwich” turned out to be even too dense - I had to press hard on the glass,to squeeze it into the frame (and lime so much lubricant that any nightclub would envy). As a result, I managed to push the glass into the frame, but I will be able to pull it out - time will tell. I hope I still never have to remove it.
Close-up picture of the picture.
Notice: the blue and white colors overlap slightly. In the photo, blue seems to be very heterogeneous, but in fact, it looks much better. This happened because white is shown on the “right” side, and blue is on the “inside”.

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