Screen Door - Mortised hinges, haunched M&T joints

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Project by unisaw2 posted 03-29-2016 01:08 PM 2232 views 3 times favorited 7 comments Add to Favorites Watch

Taking the show on the road. Most of this door was made in the shop, but it took several hours on site to demo the old door, to mortise for the hinges, install jambs, install door stops, and paint touch ups. I work slow, and it takes me a lot of time to get it plumb, level, square, and tight! Used a dime to set tolerances. (about 1/16”) The payoff is when the door closer operates perfectly, with no slamming.

Design Considerations:
Exterior installation. Illinois winters, big humidity changes. 1-3/8” thick Cedar wood, thick enough for mortised lockset. Stainless steel hinges, exterior fasteners. Painted to match existing porch. Stiles are 4-1/4” with 2-1/2” deep mortises. Top rail is 4-1/4”, bottom rail is 7”. Rail tenons are haunched 2-1/2”. Tightbond III exterior PVA glue.

New is a 31/64 Dado clean out bit, and hinge mortise jig.

The router bit has a bearing that rides on a hinge mortise jig and fense that is clamped to the door and jamb. The bit is mounted on a “trim router with a really nice led light so you can see what you are doing. Just a quick clean up with a chisel, and you get a perfect, fast mortise. The only challenge is figuring out how to clamp the jig to the work securely and have enough room for the router.

Hinge jig is from Shop notes #128 page 29.


Commissioning the van is a challenge. I always forget something,this time it was the glue and sandpaper! Weather was sunny and around 55 degrees. A good day to install this door.

Thanks for looking.

-- JJ - Northern Illinois

7 comments so far

View woodrookieII's profile


284 posts in 3079 days

#1 posted 03-29-2016 01:36 PM

Good looking door. And your attention to detail, even the smallest, is commendable and is the mark of a professional.

Nice job!


View jack1's profile


2128 posts in 4443 days

#2 posted 03-29-2016 02:30 PM

Looks great. You’ve done lots of good work.

-- jack -- ...measure once, curse twice!

View helluvawreck's profile


32086 posts in 3282 days

#3 posted 03-29-2016 03:23 PM

This is a very nice project.

helluvawreck aka Charles

-- helluvawreck aka Charles,

View Moron's profile


5032 posts in 4309 days

#4 posted 03-30-2016 02:51 AM

nice but i fail to see the haunched part ?

please explain

-- "Good artists borrow, great artists steal”…..Picasso

View playingwithmywood's profile


444 posts in 2013 days

#5 posted 03-30-2016 04:36 AM

really nice work

View unisaw2's profile


210 posts in 3451 days

#6 posted 03-30-2016 11:31 AM

nice but i fail to see the haunched part ?

please explain

- Moron

Ya I know, pictures or it didn’t happen! Sorry, I did’nt take pictures when I built the door, I’ll do better next time. The above photo shows the haunched tenon and stub mortise. The mortises were done with a benchtop hollow chisel mortiser, and the tenons were done on the table saw.

Looks great. You ve done lots of good work.

- jack1

Thanks !

-- JJ - Northern Illinois

View Roger's profile


21006 posts in 3220 days

#7 posted 03-30-2016 11:55 AM

Gr8 work JJ

-- Roger from KY. Work/Play/Travel Safe. Keep your dust collector fed. [email protected]

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