Replies

1. 
   Segil | Nov 08, 2005 12:11am | #1

   martyviz,

        I think your customer has the right idea.  Although I might not cut it down the middle.  How about to the hinge side, right where the panel starts full-thickness?  It's a judgement call based on the look of the door.

2. 
   Troy | Nov 08, 2005 01:35am | #2

   I think that biscut joint would break. I like your idea better. Another thougt would be to see if you could get ####simmilar door at a salvage yard. Good luck

   Troy

1. 
   sawdusterII | Nov 08, 2005 03:17am | #3

   It sounds like the panels are flat or you would'nt be thinking of reducing them.  What type of sticking is on the rails and styles?  It is probably a cope and stick re-enforced with dowels.  Forget the customers suggestion, you are on the right track.  Take the door apart first.

3. 
   hammer1 | Nov 08, 2005 04:26am | #4

   You may want to check out door suppliers, there's a good chance the design is still available. It will probably cost less than taking the old one apart. Here in New England, a good source is Brosco.

   http://www.brockway-smith.com/

   Beat it to fit / Paint it to match

4. 
   Segil | Nov 08, 2005 01:25pm | #5

   martyviz,

        I should elaborate a bit on my previous post.  Biscuits are fine on the panels, but on rails, you will need to use either dowels (1" x 6") placed appropriately, or a large spline (3/4" x 3 1/2" x full length) dadoed in top and bottom.  You must decide if this door receives so much stress, that this might be structurally insufficient.  I only hesitate to dismantle the frame because when I have done this, it all but destroys the door.  If you feel you can pry it apart with minimal damage, that is the way to go.