External door refurb.

[rs6mra]

Hi,

My front door needs renovating and after having had 3 carpenters/woodworkers in to quote for the job none have got back to me so I am going to tackle it myself.

Firstly I need to replace the panels, what can you suggest I use. I had hardwood panels in mind but I have struggled for find any sort of wooden panels yet alone hardwoord. Plywood seems to be the next best alternative and if this is the case I suppose its going to have to be exterior grade. The finished door will be painted.

The job appears to be fairly straight forward (but nothing ever is) and i was planning on taking the existing panels out, using a slot cutter on a router to cut a grove around the inside to a depth of 1/2" and then put a strip of plywood 1" wide on the inside. The reason being that the panel can sit on the plywood and that if water penetrates it would stop it from getting to the insides and lastly to pin the mouldings on to.

Any other suggestions would be most welcome as to how to go about doing this project.

Thanks

 

[PAC1]

I can understand why no one wants to tackle it, if you think that is straight forward. Can you take a picture from the inside so I can understand your plan

 

[rs6mra]

As requested please see the pics attached of the door from the inside.

 

[Mike.S]

The panels don't look too bad to me. Are you sure they need replacing, especially as the door's to be painted?

Suitable panels can sometimes be found by recycling old (i.e. not modern chipboard/MDF) wardrobe sides/backs, depending on thickness required. Otherwise, I believe it's a case of making your own by joining suitable planks together.

 

[Racers]

Why not replace the whole door, you then could have double glazed windows and more security, I hope that Yale lock is a deadlock!

Pete

 

[rs6mra]

making my own panels is what i will struggle with due to lack of suitable clamps and planer/thicknesser if required.
The door was filled and made good a few years ago but its took a battering from the weather the same weak point has reappeared at the bottom right hand of the panel.
As the door is to be painted i don't think finish would be that good especially around the panel and hence the reason why i want to do it correctly this time around.

 

[rs6mra]

Why not replace the whole door, you then could have double glazed windows and more security, I hope that Yale lock is a deadlock!

Pete

Replacing the door is not an option as it is not a standard sized door and would have to be custom made and I obtained a quote to do this which was 6 months ago @ £3.6k!

 

[Racers]

£3.6K! sounds like they didn't want to make it, or it was a certain double glazing firm, I bet you could make one your self, or get a local carpenter to make you one for a lot less.

Pete

 

[PAC1]

The beading on the inside could be leavered out fairly easy with a chisel and mallet. No need for a router to go anywhere near it. However what happens next depends on what you find. So first get two temporary plywood panels to place in whilst you work on it. It may be the panel is just sat in a rebate in which case it will come out no problem. It may however be in a groove in which case it will be difficult. If you have no means of making a new panel it is difficult to see how you can proceed yourself?

 

[rs6mra]

The beading on the inside could be leavered out fairly easy with a chisel and mallet. No need for a router to go anywhere near it. However what happens next depends on what you find. So first get two temporary plywood panels to place in whilst you work on it. It may be the panel is just sat in a rebate in which case it will come out no problem. It may however be in a groove in which case it will be difficult. If you have no means of making a new panel it is difficult to see how you can proceed yourself?

Thanks. I'll make a start with your suggestion by removing the beading on the inside and fingers crossed there is just one panel there and that it is not sat in rebate. I had a look at it earlier and I did question if there was one panel or two for the simple reason that there are pins that appear to hold the panel in place on the outside. I will have my plywood panels on standby but if I can remove the panels easily then ideally where can i get suitable replacements from as per my initial question?

 

[Racers]

It might be that the outer panels are just thin ply nailed on I would have a go at removing one.

If you use solid wood you need to allow for expansion that's why panels are fitted into a slot.
The method you are suggesting you will need to use ply.


Pete

 

[blackrodd]

With beading around the panels like that, it will more than likely be quite an old door and the timber will be, in my opinion, really good quality, I would repair it, if the door were mine.
The panels look to be rebated in place and skew nailed around the edges, and the rebated beading on that,
pinned into the stiles.
Carefully Remove the inner beading from the sides first as the beads may helpfully bend, start above or below centre to hopefully miss the centre nail that's likely there, remove the top and bottoms last.
I'd use bead and butt t&g. primed and undercoated first, then fitted in as panels but keeping 2, mm apart to allow the inevitable width expansion and 2mm gap around the perimiter, fix 1 nail centre in each board, top and bottom again alowing movement.
If the beads broken find similar mouldings from the Richard Burbidge area of any of the local merchants or some sheds
stock.
Do not use any acrylic primers or undercoats no good outside! I use Dulux silver primer, oil based undercoat and top coat of you're bosses choice.
HTH Regards Rodders

 

[rs6mra]

Hi Guys,
I started working in the door about 20 minutes ago and to my surprise the panels are not rebated in place.
There is beading on the inside and the plywood panel seats on the beading with external beading holding it in place.

What would you advice? As much as i would like to replace with the same, it surely isn't the most secure way to deal with this; correct?

 

[blackrodd]

I would just replace new for old, where replacement is needed with the Richard Burbidge moulding I mentioned.
As long as it is all fitted snug and well pinned there should be no problems.
The end result should be just as strong and secure when finished
Regards Rodders

 

[rs6mra]

That is what i have decided to do but at least one panel needs to be replaced as it is rotten at the bottom and so is part of the mouldings.
The question is do i replace the panel with plywood as its going to be painted and plywood is what is currently there.

 

[RobinBHM]

Why not replace the whole door, you then could have double glazed windows and more security, I hope that Yale lock is a deadlock!

Pete

Replacing the door is not an option as it is not a standard sized door and would have to be custom made and I obtained a quote to do this which was 6 months ago @ £3.6k!

I wouldnt mind getting £3.6k for a single door set!

I would say that between 3 to 4 times overpriced (for a new door + frame, painted, installed)

The door is not very well designed for external use, the beading is likely to trap water, resulting in ingress of moisture over time.

 

[blackrodd]

Difficult question to answer, without seeing it all but I would replace like for like, and therefor ply for ply.
In this case.
If you don't wish to buy a full 8'x4' sheet, for the replacement panel, wickes etc sell 4'x2' sheets which should suffice,
at around £10, or£12. Prime and undercoat well with the exterior paint for a good lasting job.
HTH Regards Rodders

 

[Mar_mite]

Why not replace the whole door, you then could have double glazed windows and more security, I hope that Yale lock is a deadlock!

Pete

Replacing the door is not an option as it is not a standard sized door and would have to be custom made and I obtained a quote to do this which was 6 months ago @ £3.6k!

I wouldnt mind getting £3.6k for a single door set!

I would say that between 3 to 4 times overpriced (for a new door + frame, painted, installed)

The door is not very well designed for external use, the beading is likely to trap water, resulting in ingress of moisture over time.

You would build a new door/frame, install it and paint it for £900?

 

[rs6mra]

Pleased to say guys that this is the door so far. Thanks for your input

 

[blackrodd]

Very well done! You've made a nice job of that, looks like you found the rebated beading.
You should have several Brownie points for that from you're Leader!
Regards Rodders