DIY Network

Salvaged Door and Cork Wall Installation From "Home Transformations" episode DHTR-110

The Kukuk family not only welcomed a third child recently, but dad Paul has also been asked by his company to open a home office. Paul will need some peace and quiet in which to work -- a tall order with three kids under the age of five.

The Kukuks have a small garden shed in the back yard that would be suitable -- but is badly in need of renovation. The space is dark and fairly cramped, with little ventilation and no storage.

In part two of a three-part transformation, host Michael Ray Wisely will guide the Kukuks through repair and installation of a salvaged door and wall cork installation.

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Salvaged Door Installation

After a trip to the salvage yard and the selection of a door that will be appropriate for Paul Kukuk's exterior home office, host Michael Ray Wisely guides Paul through squaring the door, glazing the glass and building a new door jamb.

	A salvaged door makes a great match for the new windows in Paul Kukuk's home office.
	A cork wall is a stylish and functional addition.

Materials:

Circular saw
Chop saw
Level
Ruler or yardstick
Clamps
Saw horses
Miter saw
Utility knife
Caulk
Chisel
Hinge jig
Plunge router
Nail gun
Finishing nails
Level
Measuring tape
Screws
Wood glue
Shims
Jamb stock
Irregular or salvaged door
Primer and paint

	Figure A
	Figure B
	Figure C
	Figure D
	Figure E
	Figure F
	Figure G
	Figure H

1. First, make one side of the door straight. In this example, the existing hinge stile is made level.

   
   

2. Clamp a straight edge to the stile, then use a circular saw to cut off old hinge mortise (figure A). Use the new straight edge as a reference and square remaining three sides of door.

   
   

3. To glaze the glass panes, first remove all stop in each of the door windows. Carefully score the paint line with a utility knife (figure B) and gently lift the wood stops and glass away. Be sure to wear gloves when handling the glass.

   
   

4. Measure the panes, then cut new stops with a miter saw (figure C). Install new pre-cut glass with a tempered margin around all sides.

   
   

5. Before installing the glass, caulk edges to seal the glass (figure D).

   
   

6. Install new stops with finishing nails (figure E). Once the glass in installed in the panes, caulk edges and sand surface before priming and painting as desired.

   
   

7. If you're using a non-standard size door (as many salvaged doors are), you'll need to create a custom door jamb.

   
   

8. Measure the door and add 3/16" clearance to the width. Use chop saw to cut jamb stock to size.

   
   

9. Glue top and side jamb stock with wood glue. Insert nails to secure the stock as it dries.

   
   

10. Mortise the hinges on the hinge jamb side. Use a mortising template to mark position of jambs and route to template using a plunge router (figure F).

    
    

11. Once mortises are cut, attach side stock to top jamb stock. Add door to jamb and use shims to ensure correct spacing.

    
    

12. Secure jamb with screws. Once hinge marks match the door, cut hinge mortises on door.

    
    

13. Turn door on its side and use plunge router to cut hinge mortises (figure G). Mount hinges onto the jamb.

    
    

14. Use scrap stock to keep the jamb rigid and square as door is installed. Finally, use shims as door is fit into place and secured with screws (figure H).

Wall Cork Installation

Buy cork on a roll and cut to length ...

... smooth mastic on wall to adhere the cork ...

... and finally, after applying cork, use a roller/brayer to smooth out air pockets and create a smooth surface.

RESOURCES :

Cork Wall
Brand: Badger Cork
Color: Natural
Amorim Solutions
26112 110th Street
Trevor, WI 53179
Phone: 800-255-2675
Web site: AmorimSolutions.com