Hi Croffer
I noticed that "The Ben Huggins' Project" on Sky tonight covered the making of a stable door so I recorded it in MPEG format. It lasts about 12.5 minutes and took up 750 mb of memory (or it did until until I started editing and rendering it - goodness knows what the figures will be when I've finished). You're welcome to a copy, if you can suggest a method of sending it to you!
Actually, you don't need to see the video because he essentially used tenon and mortice joints to construct two square frames with T&G panels inset. Of course, as with any door, no end-grain was exposed at the top of either frame. He then rebated the top of the lower frame and bottom of the upper frame so that both doors overlapped and a weather-tight seal was created. Finally, he hung the lower door and then the top door, placing a couple of thin shims between them so they didn't bind.
Heavy duty steel hinges on ball bearings were chosen because the door was made of oak. He also made a jig to set the hinges, 2 for each half, which I thought was quite sensible given the number of hinges and the peculiar shape.
Hope this helps.
Gill
