Well, late last night, went out and bought two packs of sandpaper, 60 grit & 100 grit. Gave the pine a good sanding all the way around, with both grits in a Palm sander. Dusted the now smooth mess off. Gave both faces of the door a good thick coat of Kilz Exterior Primer, and let it set overnight.
Somehow, I managed to get paint on 9 out of 10 fingers, AND the door, and not one other thing in the entire shop!
Ok, this morning, brought the door up out of the Dungeon Shop. Cloudy, misty day. Almost like in the Dungeon.
Set up a door vise. Clamped the door into the ex-mortise jig and added a block of wood at each end. Trying to keep the door from walking across the Kitchen floor.
Held the door to the opening….AFTER I had removed the old metal door. Little wider than needed, but the height was spot on. A #5-1/2 Jumbo jack plane then proceeded to remove the excess lumber, while also making a 5 degree bevel to help the door close. Trail fit, little more trimming down in a few spots. Marked out where the existing hinges were, and a hammer and wide chisel to mortise out for the hinges.
Test fit( I do a LOT of this) show it would fit, almost. Fine. Installed the door on the existing hinges. Check the closing action…..sticking a bit, just above the lock rail. Low angle block plane, set a bit deep ( Hey, it WAS a might on the chilly side out there) and pared away the sticky part. Closed the door to check things out
We have a fit! Into the existing frame, using the existing hinges. Needed to drill three holes, and drill them again, bigger.
Why? I have the old latch to install, of course
Not the best one, but it will do for now. Reinstalled the closer spring….needs a bit of adjustment, to allow us older, WIDE bodies to get in. Need to go and build a screen frame. Add another coat or two of paint, and try to talk the Boss out of using that can of UGLY green paint on my NEW door.
BTW: As muy normal luck goes, center hinge fell right on a tenon in the lock rail
Could have been just an inch lower? Nah, no fun that way.
I think the woodworking part of this project is about …..DONE!
Think THIS door is better than them “Store-bought” $90 wood doors at the BORG? Cost was almost the same…..
-- A Planer? I'M the planer, this is what I use