My shed is all enclosed now, and it's been raining a lot lately.
So I really need to make a door for it.
I bought three cedar 2x4s to make it out of
but it turns out two of them are too warped to use.
So I have to use a spruce one for one side. Cause warped doors are no fun.
I'm going to join the door frame with loose tenon joinery.
I'm starting with some slot mortises in the vertical parts.
And more slot mortises in the ends of the horizontal parts.
Next I have to make the floating tenons. I'm planing some stock down to half an inch
Then rounging them on either side on the router table.
And lets do a dry fit.
Now I need a window to go into the top of here.
And this storm window is almost the right size, but it's a bit too wide this way.
Glass cutting always makes me a bit nervous because you can
only score that cut line once or it screws up. And if the break doesn't break right,
you really can't fix it.
Yesss!
Cut like a pro!
It occured to me that maybe I can put this cut down window back in th original frame.
I'm adding a bit of construction
adhesive to help hold those corners together.
I'm cutting some rabbets to inset that window into the door frame.
So I screwed up a little bit with the width.
I only have a small ledge on either side of that window.
SO I think I'll glue a strip of wood here and here to give me more ledge.
And while I'm waiting for the glue to dry on that,
I might as well glue the floating tenons into my horizontal pieces.
With the door now dry fit together, I can see there's a slight twist to it.
I'm going to try to fix that.
With just three of those in there, I can see there's a
very slight twist. Lets put them in the other side.
Looking at this now, once a gain a very slight twist.
This part needs to turn this way.
And going back to this part here, placing two pieces of wood on there
and looking along it, you can see that's twisted. The near end needs to go this way.
I don't want to make this part any thinner, but what I can do is re-cut
the joinery here to counteract this twist.
I now have this end shimmed so it's on there a little bit crooked,
and here's my horizontal reference, and a reference on here,
And you can see now that this is now lined up
with essentially the machine over there.
So I'm re-cutting the joint to line up with the joint on this end here.
And now the same procedure with the other part of the door.
Quite a load of shims under there I had.
I'm using quite a generous amount of construction adhesive for this
because the joint is rather loose now because I re-cut it.
Construction adhesive is a great glue for loose joinery.
With the clamps removed form that, I can see which angle it settles at.
So now on this end I'm pulling it up a bit so that this part is
parallel with this part, and now I'll have to let the glue dry.
So now with this dry fit, it's a wee bit over the workbench here, but
the amount of remaining twist is so small, I think I'll just ignore it.
Construction adhesive needs moisture to cure,
so I'm adding a little bit of water to the joint area to make that go a bit faster.
I shimmed it underneath here and weighed it down just to counteract
the natural twist that's remaining. Hopefully once it's dried it will be completely flat.
Now with the clamps off it's resting just on the middle
and it is not perfectly flat, there's still a few millimeters left, but close enough.
Got a doorknob attached, plus hinges, and some crosspieces to help hold the metal.
Lets try to fit it in the shed.
I got the door propped in the opening so now i can mark
the vertical position for the hinges.
I'm using a router to cut the hinge mortises. it's a lot faster that way.
Just a quick check that the hinge mortises are big enough.
I got to shave something off the bottom of that door.
I routed this knot down first because the hand plane doesn't take that very well.
Well that fits.
Got the strike plate mounted
Now I can finish the rest of this door.
This piece of plywood goes on the inside of the door.
I glued a piece of plywood to the inside bottom half of the door,
plus a thin piece of oak where the doorknob goes, because I had to
cut out an awful lot of material to make room for this door latch mechanism.
I'm adding insulation to the inside cavity of the door.
Enjoy the sound of me cutting styrofoam.
I clad the outside of the door with steel roofing material.
That was complicated enough I'm making a video
about that on it's own, so I'm skipping over that for now.