The theater shop has one overhead door that we use to unload lumber and load up set pieces to take to the theater.   We rent the building but repairs are on us.  The door is very odd sized, 73" wide and about 7' tall.  The lower two sections are getting water damage.  So rather than pay $1000+- for a new door (and we might get evicted when the current owner sells the property and re-develops), we (the shop manager and I) re-built the bottom two sections and will install this weekend.  Less than $100 in materials, including paint and weather strip.

 

We bought some #1 joist material that was pretty knot free (and could cut around most of what was there).  We rip saw out the pith, yielding us some nice quarter- and rift-sawn stock.*  Planed down to 1 5/16" to match the upper two sections.  Bought a sheet of 1/4"  ACX plywood and got to it.  Most of the lumber was notoriously warped, but we worked around that.  Both the table saw and the miter saw bound up when sawing.  The other interesting thing is the plywood was made in 2022.  So I guess they don't sell a lot of it because it was near the top of the 12" high stack.

 

Below is the result, waiting for the glue to dry (exterior PVA)

 

 

 

 

 

 

 

 

* Just as an aside, the ripping a joist is the same process I used to make the frame for the workbench in the photo.  #1 rift-sawn knot free SYP is the result.

Will outlast the building

😁