Saturday April 20
Today was the day to install the door. First we had to finish resizing the door. We decided to split up the work. My friend worked on the recessed panels, while I worked on the door rails and stiles.
The drawing on the left is to illustrate the intended final look of the door.
The door construction was based on a mortise and tenon joint. The tenon was not all the way through, nor was it the whole width of the rail. While reducing the length of the rails, I replicated the shape of the original tenons, so that the door frame would be constructed in a similar manner as the original door. However, while assembling the reduced door, I decided that needed more strength. To do this, I added 8-inch anchor screws (2 per rail). I used a 3/4 inch auger drill to counter sink the anchor screw and a 3/4 inch dowel to cover up the screw head.
The rails and the styles have an intricate profile on the edge where the panels are slotted in. Instead of trying to recreate the profile, I made sure to preserve the profile while disassembling the door.
