Custom Wood Screen and Storm Door

By Robert Robillard on Finish Carpentry

Clamp up

Gluing and Clamping Door Parts

You’ll need three 4-ft. clamps for gluing: for the top, middle and lower joints.

It’s always smart to dry-fit your parts fit and correct any mistakes before spreading glue on everything — trust me, I’ve learned this lesson the hard way! Once you’re satisfied with the fit, remove the Dominos, apply glue to all parts, and assemble.  Prior to tightening the clamps and walking away, take some time to check for square.

Squaring door parts

I use two methods:

  • A framing square
  • Diagonal measurements: Measuring diagonals is an old, time-honored method for squaring up frames and other projects.

When satisfied that the assembly is square, and the adjoining parts are reasonably flat to each other, tighten the clamps!  Remove the squeezed-out glue with a damp rag before it hardens. I use a throw-away brush to apply glue to the Domino as well as inside the Domino hole.

Routing for glass/screen panels

Routing the Storm and Screen Panel Rabbit

We decided it would be easier to rout our panel rabbit 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 corner 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 Porter-Cable 42234 Corner Chisel self-aligns, and is typically used to square the corners of hinge and door lock recesses. It was perfect in this situation.

Porter-Cable corner chisel

This innovative tool saves a ton of time on a project like this. You can purchase the Porter-Cable Corner Chisel here: PORTER-CABLE-42234-Corner-Chisel 

Squaring routed corners

If you enjoyed this post, make sure you subscribe to my RSS feed!

About the author

Robert Robillard

Carpenter / Remodeler / Editor

Rob Robillard is “The Concord Carpenter” Rob is a builder, general contractor, carpenter, woodworker, and editor of Concord Carpenter and ToolBoxBuzz As a General Contractor and carpenter, Rob owns and operates Concord Carpenter LLC. A full-service remodeling and construction company. Rob is a recognized leader in home building best practices and a source for how-to information for building professionals. On this website, Rob covers all aspects of home construction, building science, home improvement, woodworking, remodeling, and some of the best product and tool reviews. Rob is in charge of our Tool and Product Review series - Concord Carpenter Videos where we post all of our tool reviews and video tutorials. Rob approaches remodeling and building construction with a pragmatic and problem-solving approach. He enjoys using his knowledge and experience to help and educate building professionals as well as DIYers on best practices in the construction and remodeling industry. He's a strong advocate for "raising the bar" in the construction trades and promoting the trades to youth. #BeAMentor #Green2Great Craftsmanship, quality, and pride guide his journey on this channel The Concord Carpenter's motto: "Well done is better than well said!" : Read more about Rob If you have a building or remodeling question you can have rob respond to your answer via video. Click here for more information. https://jointruly.com/robillard Invite code: x22r2

All posts by Robert »

Not what you're looking for?

Search for more articles here. Enter keywords like roof leak, bookcase, deck, etc to find your topic.

© Copyright 2019 A Concord Carpenter · All Rights Reserved