Replacement door: sun room door frame progress, and washer surprise

You know, when the outer door on the sun room finally broke, we thought replacing it would just be a simple matter of switching out one door for another that we salvaged from a shed.

How wrong we were!

There were a lot of things we discovered along the way that complicated things. For those who are new to this blog (welcome! Happy to see you here! 🙂 ), you can catch up on the saga here, here, here and here. Then life happened, and the whole thing stopped until yesterday.

Today, I am finally seeing a light at the end of the tunnel!

The first thing I did was smooth out the rough bits of the cut pieces a bit, then nail the side piece in place. I didn’t bother taking a picture at that point, because it really just looked the same as when we checked the final fit yesterday.

I had trimmed away some ragged bits of old caulking that were still attached to both frame and wall, but that bit of a gap that you can see was still there.

Once the side piece was nailed in, it was time to take off the door and work on the hinge side.

When cutting the side piece yesterday, I first cut it to the line I’d measured and marked with a chalk line, only to discover that when we put the piece in place, needed more cut off. That I was left with two long, narrow pieces came in very handy.

I used sections from the skinny end of the first piece I cut off to fill in the hinge recesses.

Since the weight of the door will be on this side, I used some wood glue on the second piece that was cut off…

… then nailed it in place, with extra nails on either side of where the hinges will be screwed into place.

Before taking the door off its hinges, I’d marked exactly where I would need to put the latch plate on the other side.

While giving the glue some time to set, I used a chisel to start gouging out a recess for the latch.

While I had been working on this, we got a call from the appliance repair guy about our washing machine, and he arrived while I was gouging, so I paused to be with him for that.

It was just last week that our new washing machine simply stopped working. No response when pushing the power button. Of course, pretty much every time we walked past it, we’d reach over and push the button. Nothing happened.

When the repair guy first called after being contacted by LG for the warranty work, and I described what was (and was not) happening, he ordered 2 parts that could possibly be the problem. They came in very quickly – in conversation, he mentioned that some of his customers using other brands have been waiting for 5-6 weeks, and he still doesn’t have their parts! With LG, the parts come in pretty much the next day.

He, of course, did the same thing we did; pushed the power button. LOL He tested the power to the outlet, and it was fine. As we were chatting, he mentioned that he has only recently started working with LG products; the company had been trying to get him to do warranty work for them for some time, and he finally agreed. I’m glad he did, because he’s the only person in the area that does! Still, he said he’s not as familiar with LG products as other brands.

After popping off the cover for the electronics at the back, he took the screws off one of the first part he was going to replace, for the power. The other one would have been the display panel. Then to check something out, he plugged it in.

It made noise.

I think we both had matching stunned faces.

He hit the power button.

It turned on.

I asked him what he did. He’d done nothing!

He checked the wires, to see if any where loose, but everything was fine.

He was at a complete loss as to why is suddenly started working.

He was also at a loss as to how to proceed. If he left it and sent the parts back, he’d half to re-order them if it stopped working again. The fact that it stopped working once, for no reason he could find, means that it could easily happen again. In the end, he decided to leave the parts with me, bill the warranty work, then if – when? – it happened again, we could call him directly, and he’d put in the new parts. Not knowing why it happened in the first place, as well as what happened for it to start working again, made is difficult for him to just walk away from the job. It just seems like there’s a very good chance it will happen again.

After he left, we started a small load of laundry, just to test it! So far, it’s still working fine.

What a mystery!

Ah, technology. I love my tech, but it does break down a lot more than the old school stuff! 😀

After that, I went back to working on the door.

While the door was hung, I had to lift it over the threshold to be able to close it. There was a large gap at the bottom hinge, but not the top hinge. In fact, the top corner of the door was hitting the frame. So while I did not need to add material all the way to the top of the frame, I decided to fill the hinge recess at the top, as well. With no hinge recesses, there should be enough of a gap at the top for the door to no longer be touching the frame at that corner.

Once the hinge side was built up, I put the top piece back. I then applied caulk to the outside of the frame pieces.

It’s amazing how just adding that white caulk over the gap made the whole thing look so much better!

The top was a different issue. Particularly in the middle, where there was a substantial section of wood missing! I’m guessing there was some rot that got cleaned out, before it was painted the summer before we moved in.

Little bits and pieces from the remaining piece cut off the side frame got used to fill in the gap, then I caulked the rest.

I lined the angle cut with the other side of the frame, but the shifting meant that left a large gap on the hinge side. Another piece of wood and some wood glue got pressed into duty to fill the space.

For now, everything is being left for the glue to and caulk to dry and cure for a while. The next step will be to hang the door again, and attach the latch plate. I picked up a quart of white exterior paint, and the whole frame will be painted.

Then, once everything is back up, the chain for the door, to keep it from blowing open too far, will be attached to the top of the frame. Once that is secure, I plan to move the shelf we’ve got behind the door, to the other side. I want to wait until the door is completely done because, right now, that shelf ensures the door doesn’t get blown open and breaking a window or something. I doubt the door can even open that far, but I didn’t want to take any chances!

So I figure, I’ll snag a daughter this evening to help hang the door, then – weather willing – the painting can happen tomorrow afternoon/evening.

Unless we discover something else has gone wrong, once the door is hung back up. The way this project has been going, that wouldn’t surprise me at all! 😀

The Re-Farmer

3 thoughts on “Replacement door: sun room door frame progress, and washer surprise

  1. Pingback: Happy kitties, not so happy washing machine, and awesome customer service | The Re-Farmer

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