OCTOBER 2010                                     Click on (most) images for a larger view.

       
       

After an exciting last month of finishing the siding, now we are putting the finishing touches of painting and closing in the meter base with siding!

 
Now it's time to get working on building the jamb for the kitchen Dutch-door!
We were so happy to have found this solid wood door on "Used Victoria"...
 

Here we are building mock-ups of how we want to construct the jamb. This will help us put our materials list together as well as figure the sequencing of building it.  We decided to laminate the profile with plywood to make it stronger, reduce cost, and prevent warping.  Our walls are 1 inch thicker than an average home because of our P2000 insulation so our jamb is a custom size.

mock-ups with scrap materials    
       

We will build the threshold out of reclaimed wood.  For the frame we have bought vertical grain fir.
A new product which we're very happy with is a "Green" series of adhesives which are low off-gassing and latex based.  We will glue and fasten for a solid structure.

mock-up of threshold assembly of materials mock-up with real materials  
       
milling the plywood inlays decided against routering the profile pre-drilling for assembly securing stops for assembly
       
readying the floor for threshold making sure the base is level filling high spots with "redskin" before applying the outside seal
       
Threshold plywood liner is fitted and flashing is marked for trimming. Outside seal is fastened to liner.
       

Redskin applied edge of liner and wrapped down between seal and flashing. Flashing is bent to reflect water spray and a final redskin strip holds it in place.

       

How often have we stepped on a poorly installed threshold and felt the rocking motion under foot? Not only is it important that the threshold sill is level but also that there is no rocking and it is fully supported. If not the stresses of walking on it will, over time, stress the door jamb and cause it to fail. In addition it is important that the threshold is protected from water intrusion event though this threshold is under cover. We wanted to be sure that if someone decides to spray down the patio the water would be properly diverted away from the wooden plates while allowing all wood components to wick and/or breathe to the inside of the envelope.

       

Assembling the door jamb was all about jugs and stops. Of course our magic glue was critical. Here is a sampling of how we did it. Videos of this process will soon be featured on our YouTube channel

  setting stops plywood spacers and stops insure perfect positioning while gluing screws suck it in and brad nails assist.
       
next comes the plywood insert which helps to prevent warping. checking final measurement slightly angled screws insure a snug fit of the final DF piece. Turn it over and here is one side of the door jamb complete.
       
repeat process for other side A piece of salvaged scaffolding will yield the two part threshold
       

But don't throw away that scrap wedge. It comes in handy to protect the finished surface while clamping the piece in a workmate for edge sanding.

while Laura runs more wires...
       

I proceed with the assembly of the threshold using countersunk screws and a plywood splint. Careful measurement insures holes look like they belong later when the door is installed.

       
magic glue to secure the joint and voila the threshold is finished. After rough trimming the ends we test fit against jamb before staining
       
a beautiful day to work inside and out! from framing lumber to brick mold custom made brick mold that is!
cutting the dado joint on the table saw we use a couple of pieces of scrap to match the two cuts. If you don't do this every day it is always good to mock things up and use a little scrap to make sure it works the way you think it will.
a simple jig clamped in a workmate supports long sticks coming off the table saw. fine finish sanding last coat of stain finishing up meter base while stain is drying.
       
Built a little platform on our staging to get us up to the junction box for the water heater. Repairing some minor leaks in the tape on the P-2000 insulation joints.
       
checking the load demand on the washer caused us to revise our wiring plan for the laundry.

Lady Bug Alert!

       
Glue is dry so we get back to assembling the door jamb. Jigs hold the parts in place for assembly Careful measuring to trim the jamb pieces Staggered overlaps in top joint come together with carful trimming cuts
       

careful measuring and precise cutting really pays off... 36-3/16

carefully dry fitting each joint

       

keeps cracks to a minimum

here a small detail cut must be made to accommodate teh transition on the threshold.

       

ready for assembly

 using our magic glue

clamping and brad nailing the joints.

Moment of truth... it fits!!!

       
does it really? Checking carefully Wow, yes it does!! The salvaged Dutch Door needs some help. So we make some DF wood filler to plug the old screw holes
       
Laura tries chiseling the hinge cutouts on a piece of scrap we decided to use the template to score the hinge outline and router much of the cutout before chiseling the corners
       
While Laura fits the hinges Thomas starts installing breakers in the electrical panel using the detailed plans we developed on the computer. Once again by doing it on the computer first its like doing it the second time when we finally do the work.
       

Arc Fault breaker

 looking for rocking. Fine job.

Sizing and locating wire clamps

cutting wires is nerve wracking.
       
strip wire to allow a clean layout Folding electrical tape over the ends allows us to place the wires in place without hooking them up. This facilitates the rough inspection. Laura gets ready to apply finish to the Dutch door.
       

Roughing up the old coat is the first step.

So thankful that I have a carefully planned layout or this stage could be frightening.

       
Using a sponge to sand the sanding sealer

right side is done and looks neat.

Using a screwdriver to scratch out the excess can be treacherous.
Oh well, more "patina"

       
Now Thomas tackles the left side And Laura does some ducting work while her varnish is drying. Panel is ready for inspection. And we interrupt this program for a Happy Birthday party...
       
sealing and insulating the intake duct is important to avoid any possible condensation in the ceiling cavity.

Buffing another coat

       

and then we cut the brick molding to length, carefully fit, glue and clamp.

       
a tiny insert completes the joint. Note the little shim in the corner to insure the door frame is flat and true

Inspecting the details, looking for flaws that might be remidied

       
Looking for a snug fit on the underside. And diverting to more electrical while glue dries. Sealing outside light boxes from the moist warm air inside the house to prevent condensation. More loving finish applied
       
 

Over prep counter plug needs special cutout and protection to fit in the tight space allotted.

Playing with a solution fro the porch light.

       
Mounting the hinges as the tension builds. With every step more and more is at stake and a screw-up at this stage would be very costly in terms of time. The only comfort we have is that if we have done it once we can always do it again. careful shimming and measuring is critical.
       
carefully pre-drilling a fine hole allows perfect centering of the screws.

another moment of truth... It fits like a glove!!!

       
wouldn't you know, our first door had to be a used Dutch door.

trimming the Tyvek

ready for strapping

strapping in place

       
Leaving a note fro future generations

dry fitting the door to make sure it will be plumb and square and then preparing the shims

     

tilting the door back to place caulking on the outside edge of plate in line with our envelope plane to prevent any drafts under the threshold.

Placing the shims and we have a door in place. Check out November to se how its secured.
       

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