NOT your average screen door: more chopping work

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Blog entry by bandit571 posted 10-12-2014 05:49 PM 1291 reads 0 times favorited 3 comments Add to Favorites Watch

Time to work on the other rail. Cleared the bench of the other items, they found a home on the panel blanks for now.

Someone asked about the use of Visegrip Finger clamps

Well, they work very nicely for the mortise jig I have. Anyway, a little better layout this time around. Last time, the mortises were too close to the ends. NORMALLY, one would leave a “horn” on each end, then saw off the excess when things were done. OOPS, well, I decided to move the mortise IN a bit, about 1” in from the ends. Laid out a few lines

On each end. and also in the lock rail area

One Lock rail gets a latch through the gap between the mortises, the other gets a hinge. Nice to have solid wood in those spots. Chop the mortises down about half way through

This is one of the double mortises, now, note the time stamp?

This is the second mortise, done halfway through. Flip the board over, and chop from the other side until it is all the way through. 1” wide paring chisel helps to “polish” the sides of the finished mortise. I also used a couple different rasps, as well. Sawed the 45 details on each end. Complete the other two mortises.

Part of the rail needs a groove cut, so a plough plane to cut a decent groove

Not quite a true 1/4” wide one, but a raised panel WILL fit in it. Time to mark out where the tenons will be

Clamp the stile ( what I was calling them long boards, sorry) in the jig. Clamp a rail ( the short boards that go between the stiles) and mark where the mortises are, and the 45 details. This was an end, same was done for the lock rail

Except I had two mortises to mark for, and two 45 details. Kind of need a lot of room doing this step

Photos look a little Olde-timey? Well, that BRIGHT overhead light, and the WHITE Pine kind of glare in the camera. Pulled the plug to take a photo, plug back in to saw a few things

Like tenons. Had this one standing up vertical to saw some of the waste off. Then laid it on a side, saw a line across to about 1/8” deep or so. Wide chisel and a mallet, whack the waste off. Pare to get close to flat, block plane and rasps to make sure it is flat. Flip it over, and repeat.

This is the bottom rail. It needed a groove for the raised panels to sit it. Wouldn’t you know it, a knot was in the way

And I needed a mortise for the middle stile

Not all that deep, will get a dowel pin through it when done.

LUNCH BREAK! PB&J with a Mountain Dew. Later will start on the other two rails. And might, just might cobble up a middle stile? After that? Stay tuned….

-- A Planer? I'M the planer, this is what I use

3 comments so far

View DIYaholic's profile


19620 posts in 2675 days

#1 posted 10-12-2014 06:32 PM

Lots of progress….

How will the screen/window be attached???

-- 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 Mean_Dean's profile


6487 posts in 3147 days

#2 posted 10-12-2014 06:54 PM

Looking good so far! Enjoy your lunch, and then it’s back to work!

Then you can relax tonight with a bourbon by the fire!

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

View bandit571's profile


20012 posts in 2683 days

#3 posted 10-12-2014 08:04 PM

Have the lock rail fitted, and the center stile fitted. Taking a long break until Uncle Charlie ( Horse) decides to left my fingers. Always tomorrow….

Screen/window will reside in a rebate. Then either a few clips or some molding to hold it in place. Have the clips on hand, just not sure I like them…

-- A Planer? I'M the planer, this is what I use

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