ROUTING THE PANEL
RABBET We decided it would be easier to rout our panel rabbet after the door was assembled. Because the router cannot achieve sharp corners, we used a Porter-Cable 42234 Corner Chisel to achieve sharp inside corners. The corner chisel is a spring- loaded chisel that is more efficient than a hand chisel, and ensures perfectly square corners.
It has a 3/8-inch cutter edge, and creates a 90-degree square corner when simply placed on any corner and tapped with a hammer. The Corner Chisel self-aligns, and is typically used to square the cor- ners of hinge and door-lock recess- es. It was perfect in this situation. This innovative tool saves a ton of time on a project like this.
HARDWARE The client did not want closers on these doors, for aesthetic rea- sons, and also wanted us to use brass hardware. After a little research, I came across a website called Van Dykes Restorers where we spied solid brass self-closing, storm-door hinges that operated with a 3/4-in. spring. I was excited at the option of being able to have these doors self-close, but as often happens in retrofitting projects we quickly fig- ured out that these hinges wouldn't
Dry-fit the door, using shims as necessary.
Mark the reveals of the door and make any final adjustments so the doors fit.
Use a circular saw with a rip guide to ensure straight cuts on the door frame.
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