This week I glued the repair into place. The fit was tight off of the shaper and needed a little tweaking with a hand plane, but was pretty flush to the front and back of the door.
After gluing on the repair, I cut the pine to length by hand and used an exterior wood filler to fill any small gaps. I sanded the surfaces smooth and primed the repair.
Next week I’ll finish the interior of the door and build the door frame. The new hinges arrived at the post office today and I’ll pick them up in the morning. They are traditional unfinished steel hinges that will be painted black to keep them from rusting.
