Now for a change of floors, we pop up to the 2nd floor and back in the master bath. We left off with trying to repurpose a set of solid wood panel doors that I cut down the middle.
We start by cutting the length of the doors down size. Simple enough – well, maybe not – we’ll see.
Once the doors were cut down I used the cut off pieces and made the filler pieces using a 2 1/4″ hole saw without the guide bit on a drill press. These were glued in place.
I arranged the hole section of each door to be next to the walls.
To hang the doors I used a euro style hinge made for thick overlay doors. These hinges will accommodate a door up to 1 1/2″ thick. I used three hinges per door.
The hinges use a 40mm hole to recess the hinge cup into the door. I made a simple jig out of a thin piece of plywood to make sure all the hinges were aligned to the door edge.
All the doors are up for their preliminary fitting. Don’t worry about the gaps. There was a major mistake staring me right in the face – can you spot it?
The doors have self closing hinges and work well on the 18″ wide doors.
The thing is when you cut a door down the middle you have to do a little reinforcing. The cutting removes one of the stiles – and that’s an important structural element.
So we’ll add a strip of wood to cap the cut side. Glued and nailed, it will keep those pesky rails together.
Here you have the mini stile finished and in place.
While this is going on, we’ll put the side supports in the cabinet – this will reinforce the hinge area. While we’re at it we’ll prime and then paint the interiors with BM Impervo Waterborn enamel. Color is the same as the ceiling.
Here the doors are painted and finished. I wanted them rustic and antiqued, my wife wants them white – well maybe I’ll get to glaze them later. The nice thing about the euro style hinge is you have three ways to adjust the hinge to give you a nice finished look at the door seam. The big mistake is right there, but I still don’t notice it.
The doors overlay the cabinet frame. It’s about this time when I realized my mistake. Have you found it yet?
For those much more observant than me you probably spotted it at the beginning. This door seems curiously lower than the other door. Why? Because I cut it upside down!
All together now…. crap.
Hang in there – we’ll fix it somehow.