I’ve been as motivated to work while it’s 100 degrees as I was when it was 30 degrees, so the shed has been sitting the past few weeks acclimating to the sun. The good news is that it has given me time to work in my nice cool basement workshop building the doors and corbels. I bought ten more 8′ long 8″ wide siding and slid five of them together to figure out how much to cut off the end boards to make a nice centered door.
After figuring how much to trim off the end boards, I clamped them together and stapled 4″ cedar trim across the top and bottom. I used 1/4″ crown galvanized staples 1 1/2″ long.
I attached the sides and center rail the same way. I used a liberal amount of Titebond III exterior glue to help hold everything together.
I flipped the door over and did the same thing on the other side. I left the door over hang the inside trim about 2″ so that the bottom of the door would be flush with the bottom of the siding. I attached one board on the back at the diagonal to strengthen the door.
I built the other door exactly the same way with the only difference being the diagonal board was going the other way.
After the weather cooled down a bit, I took the doors out to the shed to see how they fit. In a perfect world they would fit perfectly, however I don’t live in a perfect world and I’ve never built anything perfectly. So, I had to trim the doors down to size about 1/4″ and shave down one end about 1/8″ less than the top.
After fiddling around with the doors, they fit well enough for me to be happy. I used large hand screw clamps and clamped the inside of the doors to the frame opening. I then attached three hinges per door while they were clamped.
After they were hung, they stuck a little bit at the top. I grabbed my block plane and shaved away the tops of the doors so that they would open and close freely.
Installing the locking handle was a breeze. A simple hole drilled through the door allowed the stem to pass through. I then attached the inside handle with a set screw.
I needed the left door to stay put while the right door was locked, so I drilled a 5/8″ hole through the floor and used two-part epoxy to glue a small piece of 1/2″ copper pipe inside the hole.
I then attached the door hardware to the left door so that the bar would fit nicely in the hole.
I did the same thing for the top of the door except I used a 1/4″ copper coupler instead of a 1/2″ pipe.
I trimmed out the inside of the door the same way I did with the windows. I took a 2 x 6 and ripped into three pieces that were 3/8″ thick by 2″ wide and attached them with finish nails.
I’m happy with the way the doors turned out. Now on to the corbels.