[GB SISSON]

With summer winding down I got some time today to work on the passenger side front door. I decided to get a few pictures of this process. Once again I drilled out the hinge rivets in a rotten pickup truck door to use as woodie hinges. I had to weld up some of the holes I didn't need and drill and countersink the rest for #14 wood screws. I mortised them into my laminated maple front door stiles and re-drilled the hinges for oversized pins. The pins are made from an old screwdriver I got at a yard sale. I will be welding thick washers on for heads for these new pins. As on the driver's side I am assembling this door within it's opening because of the twisted shape as it mates into the cowl. The rear stile was milled to fit the door jamb and held with a temporary screw to hold it in place. Tomorrow after work I plan to rout the vertical grooves that hold the panels as well as the mahogany marine plywood splines that join the door parts together with the 3m 5200 marine adhesive/sealant and hardened star drive construction lags. With a spline as opposed to Henry's mortise and tenon, both horizontal and vertical members have a 3/8 x 3/4" deep groove and a 1 1/2" strip of marine plywood is inserted and glued in with the 5200. Strong and resilient joint, but tough to pull apart to repair.....It feels good to be back at it!