Making New Shed Doors. 10.11.2020

 This shed was on the verge of demolition.  However, it's quite close to my garden and orchard.  It would be nice to store tools in it.  I would spend a lot less time and effort carrying tools across the road from the house.  That would make gardening more pleasant.  We already store straw and some kindling in it.  The door is huge, and very heavy.  It pulled the hinge screws out of the frame.  The door itself is 4 feet wide, 6 feet tall, and has its own frame made from 2 X 4s.  

I think that a scraping and repainting would preserve the shed for another several years, if not a decade.  It needs a new plywood floor.  I can do that.  The inside framing seems fine.  The siding is T1-11, which is bad, but it's a shed, not a house.  I can clean up or replace bad pieces, seal and paint them to last a few more years.

The main problem is that door. It's incredibly heavy, and re-installing it was a temporary measure.  It just pulled the screws out of the frame again.  I decided to make a new one but make two doors, half the width, and without that 2 X 4 framing.  So they will probably weigh about 1/3 to 1/4 as much.  I found a 4 X 8 foot sheet of siding, stored in another shed.  I cut it down to 4 X 6 foot , then cut that into two 2 X 6 foot sheets.  I bought some 1 X 4 boards from Lowes during my last trip there, to cut for framing / trim.

I've been kind of dreading doing this.  It's too many infrastructure projects this year.  However, once starting, it has gone quite fast and not really difficult.  The worst part was moving the big sheet of siding, and cutting it.

Here are the sheets of siding, with the cut 1 X  4 boards arranged like I wanted them.  I used these to add some strength, and help flatten the siding which had a slight, subtle warp.

I numbered the boards and their locations so I wouldn't mess them up when they are glued and screwed together.  One door got numbers, the other got letters.

I used outdoor grade wood glue, and drywall screws.  I screwed them through the back so they would be tight and make a good glue-bond and not show or be exposed to the elements.  Then I used outdoor, paintable caulk to seal all of the nooks and crannies and edges so water wont soak in.

This morning I painted the doors with some left over house paint.  I think there is enough for a second coat, plus paint the entire shed.  Then it will match the house.  It's a darker grey than it looks in the photo.

 

 

Next I need a good dry day to repair and paint the siding above the door, install the new framing, and install the doors.  That will be a good start at having a usable garden shed.

 

Here is the shed as it stands now.   It looks decrepit and shabby.  I think putting on new trim, scraping, applying new paint, and installing the new doors will help a lot.  As it is now, I just lean the old door against it's opening, which is unsafe and looks like something out of Fargo.