I need to make an angle on the upper corner of a 5-panel door. It’s a prehung from Lowe’s and reworking the jamb is no problem. I can also rework the door styles, rails and panels, but first I have to take it apart. I was thinking maybe something that penetrates and disolves the glue? Any other ideas?
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I am picturing a door frame that is clipped to follow the roof line. Is that the case? I assume that clipping the corner of the door to match will get too close to the panel, making it look odd. If that is the case, make your own door. Taking apart an existing door will be an exercise in frustration.
As far as disolving glue, depends on the type. Water or steam will soften PVA, but will also warp the door. You're just plain SOL if it is epoxy or urethane.
Scott
I am picturing a door frame that is clipped to follow the roof line.
Close, but actually it's under a stairway. Building a new door isn't an option, since they don't want to spend more than a couple hundred. Also, I want to use the door they already have. Building a new one would have been my first choice if that were an option.
Edited 7/19/2008 2:35 am by Ted W.
I think I would set a saw to the depth of the panel and cut from both sides and finish the rest with a few hand tools.
I'd try to fake it.... cut off what you need to.... to the point you can trim, cut ,shave and then add to... build up what you have left to get the look you need... with a little forethought pretty sure you can do it... without take'n the door apart...
p
Thanks ponytl, I ended up following your advice and it worked out perfect enough. Basically, I chopped off the corner, shaped the bevel for the raised panel with a grinder with a sanding pad, getting what the grinder couldn't reach by hand sanding. Then I fabricated a rail from clear pine to match the door. I have a router bit close enough to the profile that only the most anal would notice the slight difference.
Ted, dont take the door, apart simply cut the top rail out, you can't use it for the new angled rail anyway. Slide the panel(s) out, fabricate a new top rail, cut panels to fit and reassemble. I've used long screws or dowels installed from the edges of the door, then plugged. Has worked great for a light use door to an attic or storage space.
Rich