We’ve been wrapping up big projects at work and in a bit of a rainy spell, so our cabin work has been small in scope and indoors. Speaking of doors, we have spent a good bit of the indoor time working on the door, again. This is the back door we bought last summer that it looks like we’ve not yet posted about. Eek.
So, we bought this ‘door’ in a back room of our favorite (non-big-box) building supply store. They used to have a great seconds, leftovers, scratch & dent room, which we found and prowled all last summer. There, leaning up against a wall, was my dream door. It’s a Jeld-Wen, and after we measured the existing opening, it was EXACTLY the right size. Which is weird, because the opening was a non-standard size. Even better, it was marked down from $575 to $75. Yeah, that’s right. How could we not get it? So we put it in the back of the truck and figured on installing it last fall.
Never happened. Why? Well, as we took a closer look (thinking I’d just paint/varnish it and pop it in), it turned out that it was siliconed into the jamb. Not just a few dollops for transport, but all the way around. I called Jeld-Wen and was told by the (very nice and helpful) guy on the other end that what we’ve got here sounds like a sidelight. Whoops! But, as I talked through it with him, we agreed that I could turn it into a door with some elbow grease. Gauntlet thrown.
I spent many evenings this winter in the basement, watching the Olympics and scraping out silicone-y goo from the door, then sanding it off, then cleaning it all up. The door finally looked great as did the jamb – almost like something a person might actually purchase if they had a real budget. So I called back Jeld-Wen with more questions. What should the size of the door be relative to the jamb? Hinge and knob placement? What kind of weatherstripping to use? All were expertly answered by a technical specialist (who was impressed we had gotten this far; it really truly was epic to get all the goo out of the door. It took like two straight weeks of evening sessions just to get the door free from the jamb).
Yesterday and today, it was no small victory to cut the door to length and width (width required the purchase of a fence for our saw, then when that didn’t work too well, and old-school improv). Then we routed all the hinge placements with this super-excellent templating jig, then the handleset with a door handle jig.
Cutting door to width. Luckily, we had another piece of jamb that was really straight!
Kreg Rip-Cut fence. If your saw doesn’t have a fence, this will do it.
Porter-Cable hinge jig in action.
Hinges go here!
And the handleset here. (It’s a surprise – a superb ebay find).
In case you want one – part number.
We stopped there – we actually were one jig short and though we could cut and chisel the strike plates by hand, we will have several doors to do and decided to order the matching Porter-Cable strike and latch plate jig (arriving in the next 3 days). The hinge jig truly is worth it.