I rebuilt the door on my shed. As with the side of the shed, the boards on the door were curling and starting to let the elements in; not conducive to healthy shed contents. Also as before, only basic hand tools were used.
So here's what needs to be replaced. Note the massive gaps and general poor condition.
I start by tapping the new boards together on the ground. The nice man at the sawmill cut these exactly to size. I tried to save a bit of time by painting them in the garage the night before but made the schoolboy error of not checking which side was which beforehand (tongue & groove boards are not the same profile on each side).
It's not as simple as this, though (is it ever?). I need to remove the groove from one side and cut another board lengthways to add a thin strip to the other to make this new door the same size as the old one. My neighbour generously offered to lend me his belt sander, but i scoffed at him and called him a bounder.
And by the time i'd cut down the 1780mm length of two of these buggers with a tenon saw, I'd seen the error of my ways. Too late now, let's push on.
Newly-cut narrow board added and it looks like it'll fit.
A quick lick of paint and we'll call it a night.
Fresh from work two days later, I'm checking the structure on the back of the original door. The plan is to re-use the braces and lock and scrap the rest, but before I get out the claw hammer I take a few measurements.
Ah, that's better.
Here's the gap I need to fill. And quick, before it rains.
I make some marks on the back of the new door and clamp the first brace piece in place. This picture was taken before I realised the clamps would have to be the other way up for me to be able to turn the door over and hammer the nails in. Duh. I also used a piece of string blu-tacked across the front of the door as a guide for me to follow when nailing.
Much clamping and hammering later (my son William helped me with three of the nails) and it's all done. A quick test fit revealed that the new door wasn't lining up correctly at the hinge side. The hacksaw was used to cut a few mm off the ends of the brace pieces to stop them fouling on the door frame.
There we go, it fits! Yes, it's a different colour, but I'm beyond caring at this stage. Right, what's next?
Ah yes, let's add hinges. I hadn't thought at all about how these would fit. Luckily the brace pieces were in the right places to hold the screws and only one screw on the door was blocked by a nail (indicated by blue circle). I just left this one off as there are plenty of other screws.
And now the moment of truth... will it open?
It opens! Even I was surprised at this!
A bit of drilling and filing to make a new key-hole, and the job is done. Still got the new windows to source and fit, so watch out for part 3.
So here's what needs to be replaced. Note the massive gaps and general poor condition.
I start by tapping the new boards together on the ground. The nice man at the sawmill cut these exactly to size. I tried to save a bit of time by painting them in the garage the night before but made the schoolboy error of not checking which side was which beforehand (tongue & groove boards are not the same profile on each side).
It's not as simple as this, though (is it ever?). I need to remove the groove from one side and cut another board lengthways to add a thin strip to the other to make this new door the same size as the old one. My neighbour generously offered to lend me his belt sander, but i scoffed at him and called him a bounder.
And by the time i'd cut down the 1780mm length of two of these buggers with a tenon saw, I'd seen the error of my ways. Too late now, let's push on.
Newly-cut narrow board added and it looks like it'll fit.
A quick lick of paint and we'll call it a night.
Fresh from work two days later, I'm checking the structure on the back of the original door. The plan is to re-use the braces and lock and scrap the rest, but before I get out the claw hammer I take a few measurements.
Ah, that's better.
Here's the gap I need to fill. And quick, before it rains.
I make some marks on the back of the new door and clamp the first brace piece in place. This picture was taken before I realised the clamps would have to be the other way up for me to be able to turn the door over and hammer the nails in. Duh. I also used a piece of string blu-tacked across the front of the door as a guide for me to follow when nailing.
Much clamping and hammering later (my son William helped me with three of the nails) and it's all done. A quick test fit revealed that the new door wasn't lining up correctly at the hinge side. The hacksaw was used to cut a few mm off the ends of the brace pieces to stop them fouling on the door frame.
There we go, it fits! Yes, it's a different colour, but I'm beyond caring at this stage. Right, what's next?
Ah yes, let's add hinges. I hadn't thought at all about how these would fit. Luckily the brace pieces were in the right places to hold the screws and only one screw on the door was blocked by a nail (indicated by blue circle). I just left this one off as there are plenty of other screws.
And now the moment of truth... will it open?
It opens! Even I was surprised at this!
A bit of drilling and filing to make a new key-hole, and the job is done. Still got the new windows to source and fit, so watch out for part 3.
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