[bobj3]

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

 

[bobj3]

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

 

[bobj3]

wanart

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

 

[bobj3]

wanart

The jig below will do just about all you need to make the door.
▼
http://www.routerforums.com/showthread.php?t=2641

But if you don't cut/mill down the door you will need to make a new door frame as well .
If the door was 7/8" thick you should stick with that size if you don't want to start from sq.1 with a new door frame.(hardware etc.)

You don't need a planer if you have a table saw and a sander.
Most of the Trex stock is about 5" wide,if you use it for all of the door parts it should be ok that's to say don't use the standard door size of 2 3/4" to 3 1/8" wide.
It's true that Trex will bend but a short stock should be ok .

Good Luck
Bj

 

[bobj3]

wanart

"just a bad idea to begin with"=yes
It will always look like a plywood door but if that's what you want it to look like go for it.

Plywood will not stand up to outside weather unless it's under cover.

How about some hardwood that you can stress after you make it.
Or about some Oak siding that's ruff to start with.
Or
Stress it with a power steel brush,this will pull the grain out and make it ruff.

Many ways to stress wood to get the look you want ,burn it torch, power belt sand it, power wash it, sand blast it, take a chain to it beat the hell out of it, etc.

Have a good one
Bj