Building door jam with side light from scratch

JANUARY 2011 Click on (most) images for a larger view.





	“We must look for ways to be an active force in our own lives. We must take charge of our own destinies, design a life of substance and truly begin to live our dreams.” Les Brown (American Author, Entrepreneur and motivational speaker)



milling threshold takes 2 cuts	sanding threshold cuts	achieving a flat slant	true in all directions


hand sanding to finish	Laura does some plumbing	mill for threshold splice	use countersunk screws


to clamp the splice	and glue a plywood spine	to strengthen the splice	Installing weather stripping


checking plans one more time	before assembling the side light	final sanding touchup	stops insure good fit


gluing the layers using plywood to prevent warping and finishing it off with vertical gain Douglas Fir salvaged from a clear 2x6


There are some places where a brad nailer can be used safely. Mockups and jigs and are critical to accurate assembly.


Gluing the Jam to the sidelight using our water based construction adhesive means that we need two days fro the glue to set completely.


	In the meantime we mill some brick moulding


check plans	and turn our attention to plumbing the water heater


These in wall essentials needed to be plumed before the shear wall sheathing is put in place.


final chance to insulate pipe for heat loss and sound		before sealing the cavity	Framing our "water tower"


8 inch centers create a strong platform for the hot water tank in it's home at the highest point in the house.


Once the platform was in place a thin wall created the home of R2D2 as we called him.


	Before staining, one last look at the transformation of scrap into finish mill work.


With the sidelight dry it was time to dry fit the rest of the door jamb.


One slight modification to make the threshold fit tight.









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