Home made screen door - Router Forums
 29Likes
Reply
 
LinkBack Thread Tools Display Modes
post #1 of 15 (permalink) Old 08-13-2017, 12:09 PM Thread Starter
Moderation Team
 
Cherryville Chuck's Avatar
 
Join Date: Sep 2010
Country: Canada
First Name: Charles
Posts: 14,856
 
Default Home made screen door

I have a large front porch on my house and the little woman wanted it screened in. We also needed a door to it to stop our dogs from getting out while they are sitting with us and to keep skunks and other wild critters from coming onto the porch at night. I looked at buying some aluminum extrusion for making screen frames out of and the price was way too high for the amount I need. I have around 36' of openings that are 64" high and I want 3 to 4 separate frames per opening (4 openings) so aluminum extrusions could have been as much as $1000.

I came up with another solution and that is mostly what this post is about. I decided to cut grooves in my wooden frames with a saw blade and then use the same rubber spline material to attach the screen to the frame. I first cut a rabbet in the frame about 1/2" high and about 5/8" wide so that once the screen and spline were in I could cover them with trim pieces. The grooves went in about 1/8" from the corner of the rabbet.

I used a full kerf flat top grind blade and cut grooves about 1/4" deep. I think after this first attempt that the groove should be 5/16" instead. Also I used .130 gauge spline material and I will experiment with that too as I think that a slightly larger spline might work better in this case. Which is the right size of spline varies according to the width of the groove and screen material used. I used aluminum screen instead of the more common plastic type mesh. I'm hoping that the aluminum is more dog paw resistant and also UV resistant than the plastic. I've replaced screen before with the plastic and it is far more forgiving than the aluminum turned out to be.

Initial results are promising. Although I managed a decent job I think it can be improved on. The trim pieces have about a 1/8" lip on the top edge to cover up the edge of the rabbets by the way. The pictures show the door with the grooves and rabbet cut and one section already finished. Another shows the two quick jigs I made on the DP to guide me in drilling the backset for the handles and the hole for the latch. I used the in paper template included with the passage set for a guide. I clamped the backset template onto the face of the door and just before it went through I removed it and clamped a blank piece of ply on the other side to prevent blowout. For the jig to drill the latch I had to add a cleat so that I could clamp that jig over the edge of the door. There is enough clearance available in the standard sized holes that perfection is not required when drilling. The last pic shows the finished door.
Attached Thumbnails
Click image for larger version

Name:	Screen door 002.jpg
Views:	142
Size:	973.4 KB
ID:	292809  

Click image for larger version

Name:	Screen door 003.jpg
Views:	117
Size:	620.4 KB
ID:	292817  

Click image for larger version

Name:	Screen door rotated.jpg
Views:	137
Size:	795.2 KB
ID:	292825  


Someone I consider a master woodworker once told me that a master woodworker is not someone who never makes mistakes. He is someone who is able to cover them up so that no one can tell.
Cherryville Chuck is online now  
Sponsored Links
Advertisement
 
post #2 of 15 (permalink) Old 08-13-2017, 01:58 PM
Forum Contributor
 
Stick486's Avatar
 
Join Date: Jan 2013
Country: United States
First Name: Stick
Posts: 24,503
 
Default

nicely done...
now that dogs enter into the scheme of things - add a guard...

.
https://duckduckgo.com/?q=screen+doo...ax=1&ia=images
Cherryville Chuck likes this.

This would have been the week that I'd have finished chewing thru the restraints...
If only new layers hadn't been added....

Stick....
Forget the primal scream, just ROAR!!!
"SNORK Mountain Congressional Library and Taxidermy”
Stick486 is online now  
post #3 of 15 (permalink) Old 08-13-2017, 03:03 PM
Moderation Team
 
Semipro's Avatar
 
Join Date: Mar 2013
Country: United States
First Name: John_*
Posts: 6,425
 
Default

Job well done Charles looks good!
Semipro is online now  
Sponsored Links
Advertisement
 
post #4 of 15 (permalink) Old 08-13-2017, 05:05 PM
Forum Contributor
 
Herb Stoops's Avatar
 
Join Date: Oct 2014
Country: United States
First Name: Herb
Posts: 7,338
 
Default

Chuck that is the most beautiful screen door I have ever seen, great job. How did you keep the screen tight on the finished product? I tried to reinstall screen once and it was all baggy,not tight. I threw away the door and bought a new one and have never tried to replace screens again.
Herb
jj777746 likes this.
Herb Stoops is offline  
post #5 of 15 (permalink) Old 08-13-2017, 07:40 PM
Forum Contributor
 
DesertRatTom's Avatar
 
Join Date: Jul 2012
Country: United States
First Name: Tom
Posts: 15,563
 
Default

Hey, that's a beatiful door. I also agree with Stick you need some sort of guard for the dogs. They often make mince meat out of screen material.

To tighten the screen, you have to have a little roller to press the retainer strip into a groove, which stretches the screen tight and holds it in place. I've lived with many screens over the decades, but don't have any now because it would spoil the look of the burgundy front door.

The more I do, the less I accomplish.
DesertRatTom is offline  
post #6 of 15 (permalink) Old 08-13-2017, 07:53 PM
Registered User
 
Join Date: Nov 2012
Country: United States
First Name: Richard
Posts: 2,981
 
Default

Nice

"The difference between genius and stupidity is that genius has its limits". Albert Einstein
Shop guy is offline  
post #7 of 15 (permalink) Old 08-13-2017, 07:55 PM
Retired Moderator
 
TwoSkies57's Avatar
 
Join Date: Feb 2009
Country: United States
First Name: Bill
Posts: 5,983
   
Default

Very nicely done Charles!! From what little I can see, it looks like it belongs.

"..... limited only by imagination"

"Just smile and wave boys, smile and wave"
Skipper the Penguin
TwoSkies57 is offline  
post #8 of 15 (permalink) Old 08-13-2017, 08:56 PM
Registered User
 
DaninVan's Avatar
 
Join Date: Dec 2011
Country: Canada
First Name: Dan
Posts: 13,831
 
Default

The retainer strip Tom referred to is called a "spline'' if you're shopping for it. It's extremely flexible and easy to work with.
https://www.thespruce.com/use-a-scre...n-tool-1825116

Great looking door Charles!

(Wish I had pics of the dog tearing through the patio door opening and ending up wearing the screen.)
DesertRatTom likes this.
DaninVan is offline  
post #9 of 15 (permalink) Old 08-13-2017, 11:34 PM Thread Starter
Moderation Team
 
Cherryville Chuck's Avatar
 
Join Date: Sep 2010
Country: Canada
First Name: Charles
Posts: 14,856
 
Default

Quote:
Originally Posted by Herb Stoops View Post
Chuck that is the most beautiful screen door I have ever seen, great job. How did you keep the screen tight on the finished product? I tried to reinstall screen once and it was all baggy,not tight. I threw away the door and bought a new one and have never tried to replace screens again.
Herb
Thanks Herb. Pressing the spline down over the screen and into the grooves is what tightens it up. This wasn't quite as tight as I would have liked and I think the extra 1/16" of groove depth might solve that. I've made and replaced a few with the plastic mesh type and it's fairly easy. This was my first attempt with aluminum screen and it is more difficult. You have to be careful handling it. If you bend it it has a memory and will show whereas the plastic mesh doesn't. If it doesn't go in right you can pull it back out and start over and it probably won't show. The aluminum is a one time shot.
DesertRatTom and Herb Stoops like this.

Someone I consider a master woodworker once told me that a master woodworker is not someone who never makes mistakes. He is someone who is able to cover them up so that no one can tell.
Cherryville Chuck is online now  
post #10 of 15 (permalink) Old 08-13-2017, 11:41 PM Thread Starter
Moderation Team
 
Cherryville Chuck's Avatar
 
Join Date: Sep 2010
Country: Canada
First Name: Charles
Posts: 14,856
 
Default

Quote:
Originally Posted by Stick486 View Post
nicely done...
now that dogs enter into the scheme of things - add a guard...

.
https://duckduckgo.com/?q=screen+doo...ax=1&ia=images
I squeezed the screen in between opposing muntins on the door to keep the exposed screen as stiff as possible but if there does appear to be a developing problem with dog paws then I'll cover up enough of the bottom to prevent further damage. Also one of the reasons for the grooves and trim to cover them is that I can pop the trim back off and replace the screen if and when necessary.
jj777746 likes this.

Someone I consider a master woodworker once told me that a master woodworker is not someone who never makes mistakes. He is someone who is able to cover them up so that no one can tell.
Cherryville Chuck is online now  
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Router Forums forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in











Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Similar Threads
Thread Thread Starter Forum Replies Last Post
home made Panel Carrier Cherryville Chuck Tool Reviews 37 03-28-2016 10:43 PM
Selling your home made stuff... DesertRatTom Lobby 6 10-12-2015 09:48 AM
Home made router table that is warped. godavid Table-mounted Routing 15 01-21-2013 12:28 PM
overcomming home made router table snags matey Table-mounted Routing 5 01-27-2011 07:36 PM
Home made mitre fence? normcatalunya Jigs and Fixtures 9 11-01-2005 02:51 AM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome