On Wed, 23 Nov 2005 18:20:21 GMT, Rick wrote:

The design I want is much like a castle door, thay you would see on an
old english castle (located in wales). Its 50 inches wide, and 7 foot
tall, so its not your standard size. The frame is made from 8x4 and
8x14 oak, its set in a real stone wall, so it has to have a chunky
solid look.

Genuine "castle doors" don't have frames. They're universally
flat-boarded on the outside , because exposing the framework also shows
where best to break it.

The outside will have vertical planks, and iron nail studs, with a
large heavy knocker.

The problem I have right now, is where to get the iron studs from

They're widely available. The cheap and convenient option is to use
square-headed coachscrews.

You'll also need hinges and knocker, which you'll either be making or
buying from a real smith. They'll be able to source the studs too.

As a finish, then take any zinc coating off first with some convenient
acid (even vinegar), then rust brown them (salt and warm humidity), then
blacken them with phosphoric acid. Finally oil them.

Watch out for "iron stain" if you put steel fittings into oak. best
option is to darken the oak first (ammonia gas, ammonia liquid or iron
acetate (wire wool and vinegar) in increasing darkness.
..