We recently bought a ~22 year old house that needs some work and updating. As one of my first real projects around the house, I needed a new screen door to enjoy our screened in porch. The old door had decayed to the point of falling apart. I thought this would be a great place to start with a new found hobby of woodworking.
The finished project is here: http://lumberjocks.com/projects/313826
I won’t go into too much detail here – just wanted to go through my steps.
As I have just recently moved to the area, I have yet to find a good source of wood. So, lacking the time to explore my options, I just picked up some 5/4 clear pine from the big box store. I rough cut everything and laid out what I wanted.
I decided to roughly stay with the same way to attach the screen as the old door. It used a simple rabbet with a slot cut in for the screen spline. A trim piece was then used to cover the rabbet and spline. Here is a test piece next to a section cut off the old screen door for comparison. I went with a simple beveled edge that would be easy for me to match on a table saw for a rail and stile frame. In hindsight, I should have gone with a bit more of a bevel – this one is barely noticeable and more of an angle would have helped keep it centered later in the glue up.
I ended up needing some downward pressure to keep the joint from separating. As I stated before, more of a bevel might have helped here to keep it centered.
Everything was fit into place after the glue up and then I applied a penetrating stain. The stain was a mix of Dark Walnut and Gunstock to try to match the dark, but slightly red tinted existing wood.
This is a picture of the stained frame with the unstained trim fitted in place, followed by the (nearly) finished door with screen in place.
I also coated the door (pre-assembly, then another coat post-assembly) with a deck waterproofing that had a slight tint. This will (hopefully) keep it from the elements and also helped me match the existing deck color.
Here is a final picture with the hardware on and door installed.
-- Brian - Ellicott City, MD