We had to machine all the parts perfectly square and to the exact sizes so when assembled, all the joints would meet perfectly flush and the doors would be dead flat (‘on plane’). Here we are doing a dry fit (without glue) to see if it will come together as planned.
We ended up creating three hundred and thirty-six pieces of this square molding to hold all the panels in place.
The door’s top half was fitted with tempered glass and the bottom, with wood panels.
Both storm doors and the main doors were mounted with very good hardware.
They wanted brass box door latches and completely hidden scissor hinges that were made in Germany. All of these had to be deeply mortised into all the door’s edges. We had to do the same for the corresponding places on the jambs (door surrounds). We constructed them of thick Sepele and made saddles (the floor pieces), as well. This is referred to as ‘pre-hung’ doors.
Although the painter’s tape is on the glass (they are applying the finish themselves) AND it was snowing outside, I managed to get this photo from the interior. In a few years the patina will look even better. I know they are very happy.
russell hudson / www.hudsoncabinetmaking.com
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