DIY Network

Urban Conversion (4 of 4): Installing a Pantry Door From "Kitchen Renovations" episode DKTN-308

	Host Paul Ryan and our homeowner (Erica) take an old 1920s restaurant kitchen that had been empty for years ...
	and turn it into an eye popper ...
	without losing its sense of history.
	In this final episode track lighting is installed and the finishing touches completed.

Materials for Crown Molding --

Extruded polystyrene molding
Tape measure
360-degree laser level
1/2" plywood
Screw gun
Paneling adhesive
Impulse pin nailer
Compound miter saw

Materials for Swinging Door Rehab --

Plywood
Wood glue
Impulse pin nailer
Rock hard wood putty
Putty knife
Router with round over bit
Orbital sander
Medium grit pad
Double action hinges
Screw gun
Drill

Materials for Track Lighting System --

Track
Light Fixtures
Hammer drill
Carbide drill bit
Construction adhesive
Screws
Anchor sleeves
Hammer
Laser level

advertisement

	Figure A
	Figure B
	Figure C
	Figure D
	Figure E
	Figure F

1. Fill in the existing hinge mortises using small pieces of wood cut to size. Glue the fill strips in place (figure A), and blast a couple of pin nails in.

2. Use a powder called rock hard water putty to patch around the hinges and various holes in the door. It is a great all around wood filler. Just mix with water and stir it until you get a thick paste. It dries very fast. Let it dry for 15 minutes and then it is ready to sand.

3. You need to rout the edges of the door to make sure it will swing properly. Paul used a heavy-duty router with a round over bit. The bit has a follower bearing on it that automatically guides the router along the edge of the door (figure B). Other bits may require a guide like a straight edge.

   Tip: A heavy-duty (2-1/4 horsepower) router ensures a steady RPM. A smaller motor could bog down when routing off so much wood, and the bit could bind and burn.

4. Do both sides of the door. If the router edge is not perfectly smooth, you can use an orbital sander using a medium grit pad. You can also use the orbital sander to smooth down the putty.

5. The homeowner chose double swing hinges. You attach the hinge to the door frame and when you push the door open, the hinge that is attached to the door will swing open. When you push it the other way, the hinge that is attached to the doorjamb will open the other way.

   Note: Heavy-duty action hinges cost approximately $50 - $60 per pair.

6. The hinges are made to fit any size door (figure C), so use a spacer to assure that the hinge is centered and then you remove the spacer once the hinge is screwed in place.

7. Drill pilot holes and attach the hinges with inch and a half number 10 wood screws (figure D).

8. Align the door in the center of the jamb at the correct height and then screw the hinge in place. The trick is to make sure the two barrel springs are centered in the jamb (figure E) -- do not go by the holes in the hinge.

9. Once the door is in, you need to tension the springs by turning the adjustment ring with the key provided and then insert the set pin (figure F) to hold the spring at the desired tension. It takes a little trial and error.

10. Finish the door by painting it and adding hardware (kick plates, etc.).

In the next segment, Paul and Erica install the crown molding.

RESOURCES :

8 x 34 Kick Plate
Model #: 02007587
Color: Stainless Steel
Where available: Visit the Van Dyke's website, link below.

Wind River Push Plate
Model #: 02010326
Color: Antique Pewter
Where available: Visit the Van Dyke's website, link below.
Van Dyke's Restorers
Website: www.vandykes.com

Orac Surroundings Cornice Molding
Brand name: Orac Surroundings
Model #: CX106
Color: White Polymer
Where available: Visit the Outwater website, link below.
Architectural Products by Outwater
Website: www.outwatercatalogs.com

Lighting (Tech Lighting)
Brand name: Tech Trak
Model #: 700TTA
Color: Satin Nickel
Brand name: Spot Heads
Model #: 700TTSPT
Color: Satin Nickel
Brand name: Echo Pendants
Model #: 700TTECPC
Color: Clear
Where available: Visit the Tech Lighting website, link below.
Tech Lighting
7401 North Hamlin
Skokie, IL 60076
Phone: 847-410-4400
Fax: 847-410-4500
Websites: www.techlighting.com or www.tiella.com

36" Pro Chef Refrigerator
Brand name: Northland
Model #: G536MMINSS
Color: Stainless Steel
Where available: Visit the Northland Kitchen Appliance website, link below.
Northland Kitchen Appliance
PO Box 400
Greenville, MI 48838
Toll-free: 800-233-3900
Website: northlandnka.com

Integra Design 4-Cycle Stainless Steel Dishwasher
Brand name: Bosch
Model #: SHX46A05
Color: Stainless Steel
Where available: Visit the Bosch Appliances website, link below.
Bosch Appliances
5551 McFadden Ave.
Huntington Beach, CA 92649
Toll-free: 800-944-2904
Website: www.boschappliances.com

Food Waste Disposer
Brand name: In-Sink-Erator
Model #: 777ss
Where available: Visit the In-Sink-Erator website, link below.

Sinktoo Switch
Brand name: In-Sink-Erator
Model #: STS-00
Color: Chrome
Where available: Visit the In-Sink-Erator website, link below.
In-Sink-Erator
Website: www.insinkerator.com

6-4 Series Range
Brand name: Aga
Color: Pistachio
Where available: Visit the Aga Ranges website, link below.
Aga Ranges
Website: www.aga-ranges.com