Back door has a nasty looking, white, metal screen door. Seen way better days. Have been told by the BOSS to make a new screen door.
Trip to Menards, picked out a few 1×4 x8’ Pine boards (3) a couple 1×6s and a couple 1×8s. Maybe $26+tax? Got things down into the Dungeon Shop to lay stuff out
Hmm, might get a little bit crowded down here. Laid out the parts to locate a few joints
And somehow managed to open the tool chests, to drag out a few tools
And a FIRST for me! I actually drew up a PLAN, whatever that is
Ok, I looked over the three 1×4s to pick out the best two. Third one will be for other parts. A bottom rail made from a 1×6, a “lock rail” from a 1×8, and the top rail from that third 1×4. There will be raised panels, seperated by a middle stile. First things first, mortises need chopped
Screwed a jig to the bench, right over a leg. Less bounce that way. Laid out where the tenons would go through. That is right…THROUGH. Got out the 1/4” mortise chisel, and got to choping and digging. FINALLY got through!
The secret being to chop halfway through from one edge, flip the board over and finish the chop all the way through. Less blowouts that way. A Four-in-hand rasp to clean out the insides, and move on to the next “Victim”, the Lock rail
It has two tenons. The space inbetween is for the latch to go through. Then on to the end for the top rail.
Between the bottom rail, and the lock rail, there needs to be a groove. It will house the raised panels. In the past, I’d have used the router ( even bought a new bit for this) but figured Pine was soft enough, an old Plough Plane would work
1/4” x 1/4” groove. Then a pass or two to smooth things out a bit
So far, only one mishap
When you get too close to an end, blow-outs happen. Will just finish this as a open ended one.
Next, Day two of this Fun Job? Ah, trim for the rails, as one stile is done. Now, I do the joint a bit fancy on these.
A 45 degree cut, then rebate the area where the rail meets the stile. Makes for a neater joint lline. As for that double tenon Lock rail
I used a well sharpened Marking Guage to mark the rebate lines. The ends were just sawn with a rip-filed back saw. The 45 was sawn with a little Gents saw. The double tenon reabte was a little bit different. Gauge the kines nice and deep. A wide chisel, bevel down, was then used to remove all the waste. Most just split right off. Level things out with the low angle block plane. Also, I did check the lock rail for square, then marked out where the tenons will be
And finally, before LUNCH BREAK, the lock rail got it’s groove thang done
To use one of these plough planes, you start at the far end, and work your way back. Have to keep an eye on the area where the skate is
Yes, the groove is off-set a bit, for the raised panels to sit in. Plane does throw out a LOT of curlie things, though
Well that is it, so far. Maybe after lunch, I can start on the other stile, and size the panels for a glue-up, and might even size the middle stile? Top half will need a rebate cut, to house a screen/storm window. At the rate I’m moving, might need the window first…
Stay tuned, the cussing is just getting started…
-- A Planer? I'M the planer, this is what I use