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wanart · 05-09-2006, 01:14 PM

I have an old adobe house with nonstandard exterior door sizes and I need to replace the storm door. I tried cutting down a solid core door from Larson but that exposed the particleboard core & it wicked moisture & decomposed. I want to reuse the screened window from the Larson door and build a new door from composition decking.

The problem is the joinery. Stile and rail bits for entry doors seem to start at 1 3/8". The thickness of the Trex composit decking available to me is 1 3/32". I haven't bought the decking or the bit(s) yet so I'm wide open to ideas. What can I build a door out of and how do I join it together?

Thanks for your help.

**bobj3** · 05-09-2006, 02:56 PM

wanart

Do you want to make a new Exterior Door or a storm door ???
Most Storm doors are Not 1 3/8 " thick or 1 3/32 most are 1 1/2" if it has the glass and screen type some are just 7/8" without glass insert.

Can you post a picture or two and I'm sure some one will help with your question.

Just a note Trex composit decking is not flat, you can plane it like wood BUT it will not take on glue very well but you can use poly. base type glue on it.

I just made a mail box post with the Trex stock because you can put in the ground and it will last forever..

Bj

**Mike** · 05-09-2006, 04:09 PM

You can create your own tongue and groove using a 1/4" straight cutting bit. Mark your material and plow out the 1/4" groove on the stiles. Next make rabbit or rebate cuts on the ends of the rails to fit your groove.

Gilbear · 05-09-2006, 06:42 PM

On an old house (100 years plus) I use to have (or rather, it had me) the screen doors and storms were made with bridal joints and then pegged - that could be easily done with straight cut bits as Mike was suggesting - and the look may just be in keeping with how I picture an adobe house - although it sounds like you may be wanting to get away from traditional materials - just a thought anyway!

wanart · 05-09-2006, 10:42 PM

My intent is to reconstruct the storm door that is falling apart. The existing door is about 7/8" thick. It's a 3/4" particleboard core with thin laminates on both sides. What I want to do is rebuild it of some material that is as waterproof as I can get. That is why I'm looking at the Trex composition decking material.

I didn't realize glue would be a problem. I thought that composition, like particle board and MDF, had a lot of glue in it.

I thought about tongue and groove, but the stile & rail configurations look like they would be more stable. I'm also wondering about biscuits. I haven't tried them yet so I don't know if they would be viable in this situation. Anyone have any comments?

Gilbear, what is a bridal joint? I'm not overly concerned with a traditional look, what works is more important, but the Trex decking is made to look like a wood plank so it would be in keeping with the adobe.

**bobj3** · 05-10-2006, 12:03 AM

This is what I would do.
Plane down one side only to the 7/8" then use a mortise and tenon joints on the top and bottom and the center stile, 2" long tenons then 4ea. 5/8" long plastic dowell pins in ea.joint but can only be seen from the inside of the door.
Then rabbit the inside of the door for the glass/screen ,then mortise for the hing.
This should keep rustic adobe look on the out side of the door.

Definitions of Trex

Trex is a brand name of composite material and it is a registered trademark of Trex Company.
Trex is made from reclaimed plastic and wood waste & epoxi and resin.

Resin
Any of numerous physically similar polymerized synthetics or chemically modified natural resins including thermoplastic materials such as polyvinyl, polystyrene, and polyethylene and thermosetting materials such as polyesters, epoxies, and silicones that are used with fillers, stabilizers, pigments, and other components to form plastics.

Bj

wanart · 05-10-2006, 12:17 AM

Bobj3

I didn't really follow that, but I don't have a planer anyway. What would be the advantage of making the material thinner?

**bobj3** · 05-10-2006, 12:34 AM

wanart

you said "The existing door is about 7/8" thick"

**Mike** · 05-10-2006, 12:48 AM

Wanart, Biscuits are fine for furniture indoors but a poor choice for outside use. In order to keep things simple you can build a simple half lap joint on each corner. Use a straight bit to remove half the material from each piece, place the two pieces together and you have a perfect match. You would want to use either Titebond 3 or a polyurethane glue for this project. Gorrila glue is one popular brand name. Be sure to measure the long diagonals so you are square when you clamp this up. Once your glue dries you will want to install dowels through the joint to keep it pinned in place. (Minimum of 3, 4 preferred) Be sure to use hardwood dowels such as oak, cherry or walnut. You may want to use a contrasting color rather than trying to make them match your composite. I would seek advice on the finish from a local building supply company. They will steer you to the products that will work best in your area.

reible · 05-10-2006, 01:50 AM

Before you get to excited about Trex.... I don't think it will work for a door....

"Can Trex lumber be used for deck posts or joists?
No. While Trex lumber is tough and durable, it does not have the same stiffness as wood. Therefore, it is not intended for use as a load bearing post, joist or any other primary load-bearing member."

The prime word here is "same stiffness as wood".

Ed

05-09-2006, 01:14 PM	#1
wanart Registered User New Member Join Date: Aug 2005 Posts: 9 View wanart's Gallery	Report This Post! Need advice on exterior door making I have an old adobe house with nonstandard exterior door sizes and I need to replace the storm door. I tried cutting down a solid core door from Larson but that exposed the particleboard core & it wicked moisture & decomposed. I want to reuse the screened window from the Larson door and build a new door from composition decking. The problem is the joinery. Stile and rail bits for entry doors seem to start at 1 3/8". The thickness of the Trex composit decking available to me is 1 3/32". I haven't bought the decking or the bit(s) yet so I'm wide open to ideas. What can I build a door out of and how do I join it together? Thanks for your help.
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05-09-2006, 02:56 PM	#2
bobj3 Forum Contributer Supreme Forum King Join Date: Jan 2006 Location: Littleton,Colorado U.S.A. Posts: 8,264 View bobj3's Gallery	Report This Post! wanart Do you want to make a new Exterior Door or a storm door ??? Most Storm doors are Not 1 3/8 " thick or 1 3/32 most are 1 1/2" if it has the glass and screen type some are just 7/8" without glass insert. Can you post a picture or two and I'm sure some one will help with your question. Just a note Trex composit decking is not flat, you can plane it like wood BUT it will not take on glue very well but you can use poly. base type glue on it. I just made a mail box post with the Trex stock because you can put in the ground and it will last forever.. Bj __________________ PodCast videos RWS on YouTube http://www.routerforums.com/86898-post1.html Besure and click on the Up Arrow key ▲ on the Youtube video, you can select other youtube videos on router tables http://www.woodworkingonline.com/?s=dovetail Machine Cut ▼ http://www.woodworkingonline.com/200...cut-dovetails/ http://www.woodworkingonline.com/woo...podcast-store/ http://www.woodshopdemos.com/menu2.htm Bob J.
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05-09-2006, 04:09 PM	#3
Mike Senior Moderator Supreme Forum King Join Date: Nov 2004 Location: Detroit, Michigan USA Posts: 3,372 View Mike's Gallery	Report This Post! You can create your own tongue and groove using a 1/4" straight cutting bit. Mark your material and plow out the 1/4" groove on the stiles. Next make rabbit or rebate cuts on the ends of the rails to fit your groove. __________________ Mike Please edit your profile with a name and location so we can better assist you.
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05-09-2006, 06:42 PM	#4
Gilbear Registered User Supreme Forum King Join Date: Dec 2005 Posts: 1,663 View Gilbear's Gallery	Report This Post! On an old house (100 years plus) I use to have (or rather, it had me) the screen doors and storms were made with bridal joints and then pegged - that could be easily done with straight cut bits as Mike was suggesting - and the look may just be in keeping with how I picture an adobe house - although it sounds like you may be wanting to get away from traditional materials - just a thought anyway!
	Top - Reply with Quote

05-09-2006, 10:42 PM	#5
wanart Registered User New Member Join Date: Aug 2005 Posts: 9 View wanart's Gallery	Report This Post! My intent is to reconstruct the storm door that is falling apart. The existing door is about 7/8" thick. It's a 3/4" particleboard core with thin laminates on both sides. What I want to do is rebuild it of some material that is as waterproof as I can get. That is why I'm looking at the Trex composition decking material. I didn't realize glue would be a problem. I thought that composition, like particle board and MDF, had a lot of glue in it. I thought about tongue and groove, but the stile & rail configurations look like they would be more stable. I'm also wondering about biscuits. I haven't tried them yet so I don't know if they would be viable in this situation. Anyone have any comments? Gilbear, what is a bridal joint? I'm not overly concerned with a traditional look, what works is more important, but the Trex decking is made to look like a wood plank so it would be in keeping with the adobe.
	Top - Reply with Quote

05-10-2006, 12:03 AM	#6
bobj3 Forum Contributer Supreme Forum King Join Date: Jan 2006 Location: Littleton,Colorado U.S.A. Posts: 8,264 View bobj3's Gallery	Report This Post! This is what I would do. Plane down one side only to the 7/8" then use a mortise and tenon joints on the top and bottom and the center stile, 2" long tenons then 4ea. 5/8" long plastic dowell pins in ea.joint but can only be seen from the inside of the door. Then rabbit the inside of the door for the glass/screen ,then mortise for the hing. This should keep rustic adobe look on the out side of the door. Definitions of Trex Trex is a brand name of composite material and it is a registered trademark of Trex Company. Trex is made from reclaimed plastic and wood waste & epoxi and resin. Resin Any of numerous physically similar polymerized synthetics or chemically modified natural resins including thermoplastic materials such as polyvinyl, polystyrene, and polyethylene and thermosetting materials such as polyesters, epoxies, and silicones that are used with fillers, stabilizers, pigments, and other components to form plastics. Bj __________________ PodCast videos RWS on YouTube http://www.routerforums.com/86898-post1.html Besure and click on the Up Arrow key ▲ on the Youtube video, you can select other youtube videos on router tables http://www.woodworkingonline.com/?s=dovetail Machine Cut ▼ http://www.woodworkingonline.com/200...cut-dovetails/ http://www.woodworkingonline.com/woo...podcast-store/ http://www.woodshopdemos.com/menu2.htm Bob J.
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05-10-2006, 12:17 AM	#7
wanart Registered User New Member Join Date: Aug 2005 Posts: 9 View wanart's Gallery	Report This Post! Bobj3 I didn't really follow that, but I don't have a planer anyway. What would be the advantage of making the material thinner?
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05-10-2006, 12:34 AM	#8
bobj3 Forum Contributer Supreme Forum King Join Date: Jan 2006 Location: Littleton,Colorado U.S.A. Posts: 8,264 View bobj3's Gallery	Report This Post! wanart you said "The existing door is about 7/8" thick" __________________ PodCast videos RWS on YouTube http://www.routerforums.com/86898-post1.html Besure and click on the Up Arrow key ▲ on the Youtube video, you can select other youtube videos on router tables http://www.woodworkingonline.com/?s=dovetail Machine Cut ▼ http://www.woodworkingonline.com/200...cut-dovetails/ http://www.woodworkingonline.com/woo...podcast-store/ http://www.woodshopdemos.com/menu2.htm Bob J.
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05-10-2006, 12:48 AM	#9
Mike Senior Moderator Supreme Forum King Join Date: Nov 2004 Location: Detroit, Michigan USA Posts: 3,372 View Mike's Gallery	Report This Post! Wanart, Biscuits are fine for furniture indoors but a poor choice for outside use. In order to keep things simple you can build a simple half lap joint on each corner. Use a straight bit to remove half the material from each piece, place the two pieces together and you have a perfect match. You would want to use either Titebond 3 or a polyurethane glue for this project. Gorrila glue is one popular brand name. Be sure to measure the long diagonals so you are square when you clamp this up. Once your glue dries you will want to install dowels through the joint to keep it pinned in place. (Minimum of 3, 4 preferred) Be sure to use hardwood dowels such as oak, cherry or walnut. You may want to use a contrasting color rather than trying to make them match your composite. I would seek advice on the finish from a local building supply company. They will steer you to the products that will work best in your area. __________________ Mike Please edit your profile with a name and location so we can better assist you.
	Top - Reply with Quote

05-10-2006, 01:50 AM	#10
reible Registered User Supreme Forum King Join Date: Sep 2004 Posts: 1,703 View reible's Gallery	Report This Post! Before you get to excited about Trex.... I don't think it will work for a door.... "Can Trex lumber be used for deck posts or joists? No. While Trex lumber is tough and durable, it does not have the same stiffness as wood. Therefore, it is not intended for use as a load bearing post, joist or any other primary load-bearing member." The prime word here is "same stiffness as wood". Ed __________________ Sometimes you get, and sometimes you get got. Last edited by reible; 07-15-2006 at 01:25 AM.
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