Replacing the sauna door before it falls off #1: Just replicating everything I see on the old door, except the sagging joints

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Blog entry by Antti posted 02-02-2020 05:09 PM 573 reads 0 times favorited 0 comments Add to Favorites Watch
no previous part Part 1 of Replacing the sauna door before it falls off series Part 2: Worthy opponent »

Prior this session I had jointed, glued, jointed, planed & dimensioned same wood that the is in use in our sauna.

So I started with sharp edged components, and

- made a jig from mdf and routed the slots for the hinges. The jig came out too short, so I had to iteratively move it back and forth until the hinge fell into its place.

Yeah. That is blood alright.

- installed the hinges to the individual frame component, and hung it to the door-frame to make sure I had the hinges in correct locations before proceeding

- made the mortises (with the Domino) for the first of the two tenons in each corner.

- routed (using 4 different bits!) the slot for the ”lock”

- dry assembled the frame to measure the depth for the groove for the glass, and marks where to stop roundingnover the corners. Actually I had to do the dry-assembly probably at least 4-5 times, because ”new” things kept coming up in the process.

- routed the groove for the glass

- once I knew where the glass would end, I could position &route the mortise for the second domino in each corner. The door frame are 40 mm thick and 95 mm wide. I used 12mm * 140 mm tenons, which I cut from a longer piece of the ”water resistant” version of the domino tenons.

- routed the round-overs

- glued the thing together. I squeezed some silicone every 10 cm or so in the groove, to make sure the glass would not end up bouncing loosely around as it did in the original door. For the domino joints I used Titebond 3. And again, I had my daughter help while I spread the glue, slid the glass in place, and connected all the pieces. Of course her main role was to help me hold myself together through the stressfull experiance.

So far so good. It will be a HUGE disappointment if this came out somehow crooked and wont fit the door opening! At this point I am somewhat optimistic, as the glass is probably square, and it is rather tight fit.

I still have to
- spread a thin silicone bead to the glass-wood seam.
- install the handle. It will be as tall as the door itself, and I will glue the blocks between the handle and the door as ”external tenons” in the two corners. For extra strenght. I’’ll post a picture later.
- sand off the glue drippings
- treat the wood with parafine oil

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