|Project by Steve||posted 04-09-2014 04:01 PM||3791 views||4 times favorited||5 comments|
Our back door is on one side of a bay window, so it requires a custom screen door. I used kreg Jig pocket holes to put it together. It’s made from 1” thick Southern Yellow Pine from Lowe’s and the door measures 24-13/16” x 80-1/4”.
I salvaged the hinges, door closer, and latch/handle from our previous screen door, so the only items I had to buy were three 9’ boards, screen material, and vinyl spline for about $35. I was able to save some money by making my own 1” wide wooden screen frames, instead of buying the metal ones at the store.
The glued mitered corners of the screen frames were fragile, so I recommend reinforcing them somehow. They stayed together long enough for me to screw them to the door. I noticed the wood screen doors at Lowe’s have the screen spline grooves cut into the door frame, so that might be a better way to attach the screen, plus it would eliminate the frames unless you just want to cover up the spline.
I located the pocket holes so that most of them would be covered by the screen frames. Only the ones at the very top and bottom are visible. I did not plug them in case I need to tighten them after the door weathers a while. To adjust the fit and make the gap even on both sides of the door, I did end up chiseling out some shallow mortises for the hinges.
Thanks and happy woodworking! Steve…
-- Steve in Lawrenceville, GA - http://www.TheCarmichaelWorkshop.com