Restoring an Ancient €8 Oak Door in Rural France
Renovating an old house in rural France often means facing unexpected challenges, and restoring this ancient oak door has been one of the longest and most complicated projects so far. Problems appeared at every stage, but nothing has been impossible to overcome. When we first started, the door was riddled with rot and woodworm, but because it only cost eight euros, it still felt worth attempting to save it.
Originally, this was never meant to be a restoration project at all, but once we saw the quality of the brass hardware, the plan quickly changed. Saving original features is always tempting, especially when renovating an old French farmhouse on a small budget.
Salvaging Oak From a 150-Year-Old Farmhouse
Much of the original oak had already been replaced over the years, and those earlier repairs used solid timber salvaged from a 150-year-old ceiling beam in our spare bedroom. Reusing old materials makes sense in a rural France renovation, but it also brings complications because every piece of timber behaves differently.
Replacing the remaining sides and floating panels meant finding seasoned oak, and that’s not easy when most local sawmills only stock freshly cut green oak. The issue isn’t availability, but suitability, because oak that hasn’t dried properly can warp, shrink, and fail once installed.
Why Freshly Cut Oak Can Ruin Old Doors
Green oak may look tempting, but it isn’t always suitable for antique door restoration. As moisture content drops, timber can twist and distort, and those changes can break joints and weaken grooves. That’s especially risky when working with floating panels and traditional joinery.
Although we had one well-seasoned oak panel that had been stored for fifteen years, it was far too thick. Reducing it to the required 35mm would either require specialist machinery or paying a sawmill, which isn’t ideal when you’re renovating an old house on a tight budget.
Cutting Out Rot and Planning a Structural Repair
The lower quarter of the door was beyond saving, so it had to be removed completely. Woodworm and rot had taken over, but luckily a small section of old ceiling beam remained. That allowed us to attempt a dovetail halving joint, even though I’m not a trained carpenter.
This was nerve-wracking because the door weighs around 50 kilos, and temperature extremes here range from -15°C in winter to over 45°C in summer. The door also gets full sun, so movement is unavoidable, but since the damaged section was already scrap, this felt like a safe place to practise.
Traditional Joinery, Blunt Chisels and Hidden Nails
Cutting the dovetail joint was slow and frustrating, partly because oak is incredibly hard, but also because hidden nails dulled the chisels repeatedly. Sharpening tools became a regular interruption, but patience is unavoidable when restoring historic timber.
Once fitted, the joint should prevent sideways twisting and stop the repair from pulling out. That’s the theory at least, although real-world results don’t always match the plan.
When Repairs Look Strong but Still Feel Wrong
Structurally, the joint worked, but visually it looked like the door had a patched-up leg. It might have been strong enough, but confidence matters, especially on an exterior door exposed to weather and movement.
Because of that, the search for better timber continued, and eventually a pair of old barn beams appeared on Marketplace. They weren’t straight, they were full of knots and nails, but reclaimed oak like this is often the best option when renovating an old French property.
Reclaimed Barn Beams and a Lot of Hard Work
The beams were badly twisted and bent like bananas, so hand tools weren’t realistic. A chainsaw removed the worst sections quickly, and that also helped eliminate a lot of woodworm. It may not be traditional, but practicality wins when dealing with mature oak.
After a mountain of shavings, the beam was flat, square, and twist-free. One edge was brought to a clean 90 degrees, and the faces were planed smooth, ready for thicknessing and further joinery.
Old Oak, Mystery Insects and Precision Joinery
Cutting the beam revealed large insect tracks and pupae, far bigger than normal woodworm. Even so, the century-old oak cleaned up beautifully, and there was enough material to make both sides of the door.
Transferring dimensions from the original door involved careful measuring, guesswork, and traditional techniques. Mortise and tenon joints, grooves for floating panels, escutcheons, and dowel holes all had to line up, while also accommodating a modern three-star security lock.
Restoring an Ancient Lock Without a Key
The nine-lever lock presented its own challenge because no local key cutter wanted to attempt it. Making a key from scratch became the only option, using stainless bar and flat steel. The first attempt failed, and the second worked, but worn internal bushes meant perfection was unrealistic.
Sometimes, restoring old hardware means accepting limits, because expecting flawless performance from a century-old lock is like hoping to win the lottery without buying a ticket.
Life Beyond the Door in a French Renovation
While this door consumed a lot of time, other projects continued in the background. Visits to timber yards, brocantes, preparing vegetable beds, and helping friends all come with the territory when renovating in rural France.
Plenty more projects are lined up, so if you enjoy honest renovation stories, small-budget solutions, and the realities of restoring old buildings, follow along, and we’ll see you in the next one.
👉 Watch the full video:
Vintage Oak Door Restoration: Transforming a Hidden Gem pt 1
🪵 Timeline: The €8 Oak Door That Started It All
00:00 – The epic €8 oak door rescue begins!
A battered ancient door sparks an ambitious DIY restoration in rural France.
00:24 – Bought for brass, not a restoration mission
The plan was simple: save the hardware. The oak had other ideas.
♻️ Reclaimed Wood or Bust
00:37 – Reclaimed oak takeover: old meets older
We ditch fresh timber and hunt for seasoned oak to match the door’s age.
02:32 – Side panels revolt! Reclaimed wood chaos
Green oak, warped grooves, and doubts creep in fast.
🛠️ Amateur Carpentry Meets Reality
04:00 – Novice carpenter vs oak: confidence fading
The weight, the joints, and the temperatures raise serious concerns.
05:18 – Patchwork success… but can we do better?
Structurally fine, visually questionable. Time to rethink the plan.
🎯 The Last-Minute Timber Miracle
05:52 – Last-minute oak score! Jackpot from reclamation
A frantic dash pays off with barn beams full of promise.
06:54 – Chainsaw mayhem: our “perfect” oak isn’t perfect
Bent like bananas and full of nails, but salvageable… maybe.
❄️ Flattening, Fighting & Finding Surprises
09:06 – Hours of sanding: is there enough oak to survive?
After serious effort, the beam is finally flat and usable.
10:01 – Creepy crawlies in the beam! Who’s living here?
Something bigger than woodworm has been renting space.
10:58 – Just enough wood… or is it a gamble?
Margins are tight, and mistakes aren’t an option now.
📐 Old Doors Don’t Believe in Measurements
11:10 – Old meets new: transferring and improvising dimensions
Some sizes exist, others vanished with the rot — creativity required.
🔑 The Ancient Lock From Hell
13:17 – Key cutting nightmare: no local will touch it!
A nine-lever lock with no key and no willing locksmith.
14:36 – Keys come in bizarre shapes: how to fit?
Profiles, shafts, and tolerances complicate everything.
15:37 – Previous lock tampering chaos revealed!
Someone’s been inside before… and left a mess.
🔨 DIY Key Making (What Could Go Wrong?)
16:55 – Key attempt one: partial success, epic fail
It turns, but not enough. Close doesn’t count here.
17:25 – Key attempt two: closer, but still tricky
A solid clunk, progress made — perfection still laughs at us.
😅 Final Thoughts From a Tired Amateur
19:35 – Amateur vs ancient oak: why is this so hard?
Rebuilding an oak door with reclaimed wood is brutally hard… but worth it.