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Tag: screen door projects

Throw Back To: Episode of when I took two plus years to build a screen door.

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It all started when I was gifted some Ash boards from the family farm, that were rough sawn, and stored in a shed for twenty plus years. I gladly took them home after sawing the sixteen footers in half by hand, and tossing those heavy suckers in my van.

I planed them for what felt like hours, and then had to man handle them across my jointer. Which took forever to do. This was back when I had my tiny 10″ Ryobi table saw, which kicked on full tilt, and scared me to death. Cutting 2 inch thick ash boards that were 80 plus inches in length took some doing, and set my heart to pounding. I settled on four inch wide boards by roughly eighty inches long, and two inches thick.

I then cut down four cross members, two in Ash, and two in a douglas fir that was pretty heavily knotted. It was at this point that I began to run out of warm season, and all my flat, square milled lumber got shut away in the garage for seven months.

The following spring I dug out my lumber, which was still square and decided to hand cut some mortises for the top and bottom of the door uprights. I first used a circular saw to cut two slices through the end grain about four inches deep. This was super sketchy, and my super old school, under powered Kawasaki circular saw died after a cut & a half – twice. So I finished it off with a Stanley hand saw. You know the old kind that weirdos play with a violin bow to make high pitched whiney muzak. I had to climb up on my work bench in order to get this to work.

I gathered up my chisels and a hammer and got dug in cutting away the channel where the cross members would rest. This would prove a difficult and arduous task. It took several days, and my channel was not straight, nor were they even. I took a file to them, and worked that for a few days too. It was at this point that I started to refinish a rocking chair for my very pregnant sister in law, and that took my whole season.

The following year ( this year 2022) I took some rasps to my channels, and evened them out a fair bit. I then used a brand new Dado blade to cut some even tenons for the cross members. It was an endless cycle of dry fit testing, rasping, filing, and planing until I had a suitable snug fit. Then I measured out my center line, and cut out two mortises for the third, and final center cross member. I hugged it out with a forstner bit, then used a multi tool to cut through the rest, and then hand chiseled it to a clear rectangular hole. It worked quite well. After assembling it all as a dry fit, I noticed my angles were all wonky, and then realized my flat, square lumber, was now bowed, and twisting ever so noticeably. But as I was about to begin sanding I hit the most egregious spots with a hand plane, and sort of made the best of it.

I took the time to glue the frame together. Then in each corner I drilled out a 3/8ths hole and glued some dowels through the joints. Flush cut those, and then did endless rounds up through the grits on every single surface of the door. I stopped to add copious amounts of filler, which meant no more natural wood look, but I was now going to have to paint it all white, to match the house trim.

I used an oil based primer to paint on four coats of pristine paint. Then I cut down some Cedar strips, 16 lengths in all, which would sandwich my screen mesh in place, for the two openings on my screen door. After much cutting and sanding i put the first layer in place. Cutting the mesh material was far simpler than i was imagining it would be. So i put those in place, and pin nailed my last strips on, holding the mesh as tight as i could get it.

It was at this point I placed my hardware on the door. Pilot drilling holes for the handle and a push plate. I also then hand cut in my hinge recesses. Drilled and attached those. Fought with the door for an afternoon to cut in the receiving hinge slots on the house, and hung the door single handedly (do not reccomend). I then added backing trim to stop the door swinging too far inwards and binding. Added a latch, and an extra handle, and Bob’s your uncle. Done like dinner.

I didn’t take any photos while cutting the cross member tenons, but they’re there, and I did them myself.

Back in the shop for a partial build day.

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Yesterday I milled down all of the Cedar trim I would need to fill in the inside portion of my screen door. I cut a 1x6x8ft board down into eight .25 strips, and then trimmed those to be .75 inches wide by 8ft, by .25 inches thick. I pin nailed in the first layer. Now I have to cut up and staple in place the actual mesh material. Another big step forward. Makes me nervous. I have the second layer of trim cut and ready to sandwich in the mesh material. Fingers crossed I don’t screw this up, as I only have so much mesh to work with before I’d have to order & wait for more to arrive.

Once this goes in, I’ll affix the handle, and push plate. Then we are on to hinges, and hanging the heavy thing up in the door frame. Wish me luck! I’m going in.

Waiting on mesh! Almost done the build.

The last Thursday in February.

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It holds no special meaning beyond its proximity to March, and thus March Break and the foretold lead in to spring. The winds are bitter and cold, but carry slightly more moisture than weeks passed. And are therefore more biting, and cut deeper toward the bone. A listless jab to the body on the way out for another year.

Almost two months down into the new year, and once again the threat of war looms low over the headd of Eastern Europeans, and eventually the world. Let us not forget that West Taiwan wants to attack Taiwan proper for similar land grab and control reasons. Colonialism at its worst, and therefore also its finest. Because that’s what the machine does best, slow roll over everything and everyone in order to enrich itself and crush that which stands in the way of ever increasing expansion, and the industries created to maintain it. Weee! Splat.

Perhaps the sanctions will be enough to send the incursion packing after they’ve done a few days of random, yet targeted shelling in Ukraine’s “contested” territories. I used quotes here as the only one contesting it is Putin, and his Colonial over reach across borders. Eating up another country bite by bite, like he did with Crimea. Carving up a smaller neighbour for the sake of expanding a border and reclaiming some semblance of the USSR’s control over the region. Talk about boomer energy. That’s some rose coloured, nostalgia heavy talk of returning to the past. But with heavy casualties, death and dismemberment.

On a lighter note, who wants icecream? Hard to make a segue into any topic after talk of war in Europe. But I tried, an attempt was made. So – big picture talk here. What to do with the house come Spring & Summer? I think i want to tackle the screen door again. Build one from scratch. The basement needs to get more reasonable air flow. I also invested in a bigger and better table saw late last year, and think i can do a much better job of it now, that how i did it before. Still going to be a challenge, but i think i can get it done this year! I’d also like to challenge myself to build either a table or a chair this year too. Just one chair, not a set. That sounds tedious to me. One off items are way more exciting to produce, as far as I’m concerned. Spring will also bring a new round of heavy cleaning, decluttering and a broken toy purge. Have tackled the girls closets for ill fitting clothes. Bigger kids stuff if not ruined goes to the youngest when she’s big enough for it, and clothes from older cousins & friends filter back into the older ones closet in a seemingly endless cycle. Glad for it too. Besides pant legs much of this stuff doesn’t see enough action under one kid to go into a landfill. What we don’t use/need goes to other family members in the surrounding area. I’d love to do one in one out, but sometimes that’s not the case. Swim suits get destroyed by the sun and chlorine and heavy use, so we couldn’t donate as many of those as we actually use. If you swim two or three times a day, as is the case with us during the summer, then they (swimsuits) disintegrate pretty rapidly. Girls get duck bum, as the elastic goes in the rear and a saggy duck tail appears in the fabric as it settles. Straps wear out, and whole thing sags, and then it’s just trashed after several months. Wouldn’t want to give that mess to someone else, that’s just rude.

Will need to look at my mower again this spring, see if I can convince the old girl to give me a sixteenth cutting season! Wash and clean the filters, new oil, blades sharpened, clean the spark plug, oil it up and hope for the best. Bought it in January of 2006, and has started by the second/third pull every single year since then. Doesn’t owe me much, but I’d be thankful if it kept going a few more years yet.

A taste of earlier today in this dad’s life. Sorting out laundry loads five and six. Which was the last scraps of the kids stuff, and my wife’s clothes. Then sorting out all the one off socks we seem to have accumulated. Stacks upon stacks of singular socks. Now I don’t know if the opposites have been lost, left behind places, developed holes and were thrown away, eaten or sacrificed to the washer and dryer, but I know this. One day I will go and buy bags upon bags of plain black and white socks, that fit my wife and daughters, and then I will never sort another sock again. You get 2 lbs of B&W socks, so do you and you too. I don’t want to pair, fold, stash another sock after that happens. Theme socks seem like such a good idea until no one can keep them together to get washed at the same time, or sorted and paired again after wearing them. I’ll wager good money a fair few socks are under beds throughout the house.