[ENG] Construction 75: Courtyard door (2) - wooden shutters and closing system

21/07/16 | ۩ |

At the end of the first chapter wrote about the construction of the courtyard door, I realized that one of the holes for the insertion of the hinges into the wall was lacking. Now I need to solve this problem in order to resume my work.
Removing stones would be a hard way to do it and would probably cause some serious damage to the structure. On the other hand, the narrow working area makes hard to drill a hole pointing the Dremel tool perdendicular to the wall, even by using the flex shaft.
I decide to try it anyway with a small grade of inclination, eventually breaking a diamond wheel point. The partially made hole is not very deep, but perhaps a drop of glue could be strong enough to hold the hinge inside of it.
When it's partially dry I put an L shaped segment of iron wire into the hole and I let it dry totally.
Once dried out, the glue will turn transparent camouflaging itself with the dark stone background.

Now I'm ready for the next step: The making of the wooden door.
As I already told, it will be a double-leaf door, slightly smaller than the others. This time I take direct inspiration from an old illustrations found in a book by Viollet-le-Duc, making shutters with an oblique crossbeam framework on the inside, and vertical planking on the outside.

The kind of wood and the cutting technique are the same used for the construction of the main door, so I'll make a long story short showing you the assembled door, finished with the iron knockers on the outer surface of the shutters.

A small difference between the making of the main door and this one is the use of a new kind of glue that proved to be better for this specific work: it is called "contact adhesive" and makes possible the assembling of small parts avoiding unsightly dribbles and without recurring to stronger glues, potentially unsafe.
The only issue are filaments that sometimes take form while moving away the stick from the glued parts, but they're easy to remove with a simple pick while still not set.
Anyway, I'll keep using vinyl glue for all the stone structures, as I've done so far.

Back to our wooden door: The closing system will consist in something more than the usual latch and vertical bolts: a big wooden bolt will slide between the walls blocking both shutters from the inside.

The presence of this bolt adds complexity to the construction of the jambs, but at this point I aquired some skill in cutting slate, so I succeed in making an accurate stonework.

The bolt fits into specific holes on both jambs, one wider than the other on the inside as to allow the sliding and removal of the bolt when the door is set in open position.
Normally the bolt will rest on the floor or against the wall. When time will come to open or close the door, two strong arms will surely do the job... but for now the palace is still in 1:50 scale and two fingers are strong enough.

When the walls will reach the right level, the upper hinges and any other iron part will be inserted.
But... in my previous post I talked about a relocation, so here I put a shot of the building site in its new location, a room fully dedicated to the designing and construction of the Domus!

slate, vinyl glue, contact adhesive, wood, iron wire

cutter, tweezers, pincers, sandpaper, hacksaw, Dremel tool

SIZE (in cm):
with closed shutters: 3,4 x 5,5 x 0,4
wooden bolt: 0,3 x 0,3 x 4,9
inside compartment: 3,8 x 1,9
door width: 2,6


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