This is a continuation of the "Sagging Garage Door" saga from 06-17-12.

What with the Big Heat, etc, it's no practical to repair the door.

Have been to Lowes, etc. Can't find suitable replacement.

How difficult is it to "build" a door?

I look at the rail and stile construction and think "A Mess Of 2x8's, Some
Plywood (for panels) And A Table Saw". Of course, it's more difficult than
that.

I don't need anything particular fancy, just secure and reliable/durable.

Anybody built one? Can anybody help with little details? Simple mortise
and tenon? Which (exterior) glue? Fasteners???

Thx,
P

"Law Without Equity Is No Law At All. It Is A Form Of Jungle Rule."

On Wed, 11 Jul 2012 06:56:29 -0500, Puddin' Man
wrote:


This is a continuation of the "Sagging Garage Door" saga from 06-17-12.

What with the Big Heat, etc, it's no practical to repair the door.

Have been to Lowes, etc. Can't find suitable replacement.

How difficult is it to "build" a door?

I built two 8' by 9'6" doors to enclose a dual carport a couple months
ago. 3/8" ply and tubafores, barn door slider hardware. It took me a
day and I had help hanging them. I was able to flip them myself as I
primed and then painted them.

I look at the rail and stile construction and think "A Mess Of 2x8's, Some
Plywood (for panels) And A Table Saw". Of course, it's more difficult than
that.

I don't need anything particular fancy, just secure and reliable/durable.

Anybody built one? Can anybody help with little details? Simple mortise
and tenon? Which (exterior) glue? Fasteners???

I used galv screws for the ply and galv joist plates and screws to
connect the tubafores, which laid flat.

For a hinged, one-piece door, I'd have used spruce instead of doug fir
tubafores, and ripped them into tubatwos to save weight. I might have
gone to 1/4" ply, too, or 1/8 on both sides with a foam core center.

Just build 'em square and they're easy.

--
It is common sense to take a method and try it. If it fails,
admit it frankly and try another. But above all, try something.
-- Franklin D. Roosevelt

On 7/11/2012 4:56 AM, Puddin' Man wrote:

This is a continuation of the "Sagging Garage Door" saga from 06-17-12.

What with the Big Heat, etc, it's no practical to repair the door.

Have been to Lowes, etc. Can't find suitable replacement.

Define suitable...

Lowes millwork department either stocks and can get damn near any
type door made.

I recall your door as pretty "basic".

You can also very easily buy a door "slab" from most any
lumber company or Lowes or Home Depot.

A proper door is made with proper materials and some really
large shaper bits, although there are door making kits available
for large routers.

My question would be, "why" ???

An exterior door can be bought quite cheaply.

You might even consider looking a "resale" stores like
Goodwill and many others resales shops.

Our local store usually has "many" exterior doors.

Your old door should come apart fairly easily, for you to clean up the
joints and reglue everything.

If you don't have the tools for making appropriate tongue & groove
joints, then your best alternative, IMO, is lap joints. Lap joints
for that door would not look bad, especially if the door is to be
painted, and may be easier to make.

On Wed, 11 Jul 2012 08:06:41 -0700 (PDT), Sonny
wrote:

Your old door should come apart fairly easily, for you to clean up the
joints and reglue everything.

Maybe I'm just too particular, but any joint which has failed will
continue to fail repeatedly until it breaks. I refuse to attempt
repairs on such joints. I replace the pieces or build new.

--
It is common sense to take a method and try it. If it fails,
admit it frankly and try another. But above all, try something.
-- Franklin D. Roosevelt

On 7/11/2012 10:21 AM, Larry Jaques wrote:
On Wed, 11 Jul 2012 08:06:41 -0700 (PDT),
wrote:

Your old door should come apart fairly easily, for you to clean up the
joints and reglue everything.

Maybe I'm just too particular, but any joint which has failed will
continue to fail repeatedly until it breaks. I refuse to attempt
repairs on such joints. I replace the pieces or build new.
....

OP posted link to pic in another newsgroup month or more ago--it's a
basic panel door that has the typical failure of an old door.

I've done numerous similar over the years--unless one finds there's
interior hidden rot, virtually always they can go back together as good
as new and last another 20 yr or more...and OP doesn't have "the right
stuff" to make replacement parts from scratch--he's said his extent is a
small 1/4" router for shaping...

--


--

dpb, wrote the following at or about 7/11/2012 1:11 PM:
y joint which has failed will
continue to fail repeatedly until it breaks. I refuse to attempt
repairs on such joints. I replace the pieces or build new.
...

OP posted link to pic in another newsgroup month or more ago--it's a
basic panel door that has the typical failure of an old door.

I've done numerous similar over the years--unless one finds there's
interior hidden rot, virtually always they can go back together as good
as new and last another 20 yr or more...and OP doesn't have "the right
stuff" to make replacement parts from scratch--he's said his extent is a
small 1/4" router for shaping...

Thinking back in my mind's eye to his first post, I'd have to agree.
Knock it down properly, clean up the joints, reglue and clamp it
square... Gild the lily if you wish by carefully boring a couple of
holes ( 1/4" or 3/8" or so) through the stiles and into the rails, after
the glue has dried, then score appropriate dowels longitudinally, glue
them in the holes for a "poor man's mortise and tenon" just to add some
suspenders to your belt.g

Easy enough to do and, as you say, if there's no rot, he should be good
to go.

On Wed, 11 Jul 2012 08:21:08 -0700, Larry Jaques
Maybe I'm just too particular, but any joint which has failed will
continue to fail repeatedly until it breaks. I refuse to attempt
repairs on such joints. I replace the pieces or build new.

That doesn't necessarily follow. Maybe the original glue was
inappropriate. Maybe not enough glue was used in the first place.
Maybe the door wasn't clamped properly. ~ Always a number of reasons
why a joint can fail.

On Wed, 11 Jul 2012 19:44:36 -0400, Dave wrote:

Thanks.

If the door and the opening both looked "funny" and I couldn't explain the
effect of one on the other, I'd take Larry's position and seek to make
both 'true'.

As it is, only the door seems to be a problem, so I concentrate on it.

Cheers,
P

On Wed, 11 Jul 2012 08:21:08 -0700, Larry Jaques
Maybe I'm just too particular, but any joint which has failed will
continue to fail repeatedly until it breaks. I refuse to attempt
repairs on such joints. I replace the pieces or build new.

That doesn't necessarily follow. Maybe the original glue was
inappropriate. Maybe not enough glue was used in the first place.
Maybe the door wasn't clamped properly. ~ Always a number of reasons
why a joint can fail.

"Law Without Equity Is No Law At All. It Is A Form Of Jungle Rule."