I think I called this door everything in the books, Army, Squid,Jarhead, Air Farce.   Now, I get to call it......DONE! 

 

Got that thing up out of the Dungeon Shop this morning.    Removed the old POS metal door and threw it aside ( Scared a Tom Cat OUT of the yard, mine you)  And test fitted the NEW door.  

 

Hmmm, height was spot on ( Of COURSE!)  but the width was a bit too wide, like me.  So, a few toys..er...tools were brought up.   A door vise was cobbled from the Mortise Jig, and the door clamped into it.  A #5-1/2 Jumbo Jack plane was then ran down the closer side.  The idea was to not only remove the excess wood, but make a 5 degree or so bevel to help the door shut.   Test fit again, close, a little more off.  

 

After a couple more such test fits, I marked out where the existing hinges were, and chopped a mortise for them in the door's edge.   Hanged the door ON the hinges, and yet another test fit.  Meh, right above the lock rail, and on up, door was bulged a bit.   Set a low angle block plane a bit deep ( hey, it was a little bit chilly out there, no time to mess around) and planed until the door just slid home.

Something like this.   No latch, it is just sitting there.   The lock rail hinge had landed right on a tenon

Why couldn't have been just an inch lower, then it would have hit right between the two tenons.  

 

Got the old latch( it will do until the Boss decides a new one is needed) and drilled a few holes ( IN MY NEW DOOR?!) and installed the latch

And...it even WORKS!   The spring return is on, as well....will need a bit of adjustment, to allow us wider bodies to come through.

 

Maybe a second coat of primer?    Need to go and build a frame for the screen, so this can be a Screen Door.  

 

Not too bad?

Awesome Job! Not bad at all!!!

Not too bad, indeed. 

Screen frame has been made, a screen cloth added to it.    A few screws and clips to install a screen in the screen door.

 

Spring has been adjusted, still gives that " SPROIIIiing" when you open or slam the door shut.  

 

Next up? Well, I have a saw I picked up over the weekend for a $1,  Needs a lot of TLC to bring back to life.   Might take a while....

And DONE it is.    You put paid to that job O work, you did indeed.

And a fine door you have for it too.

I have screen doors I gotta do.  Your  posts are an inspiration.

Not too bad at all Steve, hand made, well done, bullet proof, it will not come apart at the joints, and you made it happen, my hat off to ya pard.

Awesome job Steve and a great inspiration and demonstration on how to do it with hand tools.

 

Great Door and a job by a great craftsman!