Storm door

[davebodner]

My wife wanted a storm door for the back door. I would've bought a cheapish aluminum storm door, but my opening was just barely too narrow for any of the standard sizes. Instead of incurring the cost for a custom door, I decided to roll the dice on buying expensive wood and trying to make one.
download/file.php?mode=view&id=52761
I'm pretty happy with the result. Clear fir, stained and shellacked on the inside and painted on the outside. Haunched tenon construction and glued with Titebond III. The windows are puttied on the outside. You might be able to see the smudges on the glass from the putty that I'll clean off after it dries.

Just about everything you'd think could be done on the Shopsmith was, including tablesaw, jointer, planer, bandsaw, and belt sander. This was my first time using the tenon jig, and it worked out. Only one tenon was cut too thin, so I glued on a strip of wood and cut it again. The dado stack cut the dados and fine-tuned the tenons that needed it. The bandsaw shaped the tenon haunches. The belt sander handled the initial sanding before continuing with the random orbit sander. Unlike some of my other projects, this one glued up pretty flat and square without any jiggling.

The hardest part was flattening 4.5" boards on the 4" jointer. I tried one of the on-line techniques, but I failed. I ended up fixing it with a hand plane before the boards hit the pro-planer.

Due to my lack of planning, the upper window is taller than 36", so I had to buy tempered glass. Forced to be safe.

[edit] Sorry about the picture rotation

[john]

Looks good to me!

Even if it is side ways.

John