THE HANDMADE DOOR

(Page 4 of 4)

November/December 1990
 
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Lay the boards side by side, and mark out the rough door with a framing square (leave it a little wide; joining and clamping will reduce the width. Draw four faint pencil marks across the face, equidistantly spaced (see drawing, to locate the bore holes. Next, tun each board through the joiner to dress both edges.

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Now for the fun part. Drill countersunk holes in the outer boards only, to hide the nuts and washers; and then run each board through the drill press to make the axis holes. You can make the holes a little larger than the diameter of the 1/2" threaded rods, but take care to place them exactly in line with the pencil marks.

Glue time. Use either construction adhesive in tubes to place a thin line of glue down the center of each edge, or a brush to paint both edges with slow-setting wood glue. Use the bar clamps to clamp the boards together, but not so tight that the door cups.

Now run the threaded rods down their channels and snug them up, ever so gently, top and bottom rods first. Don't torque any single nut to maximum; alternate from nut to nut, taking out the slack as you go and wiping excess glue as it squeezes out of the cracks. Glue in wood plugs. Allow all glue to set overnight.

In the morning, your door will be ready for final trimming, edge beveling and sanding to remove any glue that remains. After that, you're ready to hinge and hang.

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