This is a pair of very old double Barn doors that I recently had to replace with new, and a bit of a task it turned out to be.
The making of the new doors was a relatively easy task which took place off site at my workshop.
I made a preliminary visit to measure up and take a few photos and make notes about such things as the placing of the original fittings, protrusions of the stone rebates and threshold levels etc etc.
This is the view from the inside and shows the different heights of the threshold (floor level) from one side to the other. That's the first problem that had to be dealt with.
It also shows the poor state of the original doors. This side was not even hung on hinges just secured to the central upright and that's all !.
The external wall sloped back, and opening slanted out from bottom to top, so there were many problems to overcome to upgrade these doors.
I decided to make a pair of slightly oversized new doors in order that I could trim them to size when fitting, but first the threshold had to be levelled across the whole opening and this was carried out by the builders whilst I made the doors.
I used 30mm thick rough sawn planking that was 220mm wide boards and I planned the edges and made 300mm biscuit joints to join enough boards to make the doors, which I then braced appropriately to strengthen and support.
Because the doors were to take the direct effects of the weather due to their position as an additional precaution I made 40mm wide strips which I glued and pinned over each joint, thus providing the appropriate protection and also making the doors asthetically pleasing.
When fitting, I had to replace the original hinging and fit new on the lefthand door, as well as fitting a door lining on each side and plane down the existing oak lintel above to ensure a smooth opening.
Additionally, I had to grind out some re-inforced concrete in order to fit the linings and remove some internal floor all to make a good fit and opening, Like they say 'no job is straight forward', however at least now the new doors perform as expected and I think look wee bit better than their predecessors, or at least they will when stained.
Recent Comments