NOT your average Screen Door?

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Blog entry by bandit571 posted 10-08-2014 04:24 PM 2103 reads 0 times favorited 5 comments Add to Favorites Watch

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

5 comments so far

View Smitty_Cabinetshop's profile


15369 posts in 2645 days

#1 posted 10-08-2014 06:03 PM

Very strong work, Bandit! Thanks for all the pics, nice job on those through-mortises.

-- Don't anthropomorphize your handplanes. They hate it when you do that. -- OldTools Archive --

View DIYaholic's profile


19623 posts in 2702 days

#2 posted 10-08-2014 09:23 PM

My only question….
How many Mountain Dews will be harmed during this build???

-- Randy-- I may not be good...but I am slow! If good things come to those who wait.... Why is procrastination a bad thing?

View gfadvm's profile


14940 posts in 2717 days

#3 posted 10-08-2014 11:44 PM

Very impressive. I wouldn’t know where to start with handtools on this one.

-- " I'll try to be nicer, if you'll try to be smarter" gfadvm

View Mean_Dean's profile


6567 posts in 3174 days

#4 posted 10-09-2014 12:08 AM

Looking good so far! Will keep up with this blog, for sure!

-- Dean -- "Don't give up the ship -- fight her 'till she sinks!" Capt James Lawrence USN

View waho6o9's profile


8207 posts in 2603 days

#5 posted 10-09-2014 03:37 AM

Nice joinery Bandit, thanks for posting.

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