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Author Topic:   Console Door Frame Re-Build Project

westcoastwhaler posted 11-06-2009 05:57 PM ET (US)
My winter project is to build a new set of teak doors and frames for my Outrage '22. I have the originals and plan to duplicate them in teak.
The OEM frames are joined with glue and dowels but over time they have become structurally weak and separate a bit at the seams. Also, the doors do not fit flush (I believe this is a hinge issue).
I am soliciting ideas about a better method for joining the corners. Any thoughts are welcome.

Stevebaz posted 11-06-2009 07:04 PM ET (US)
When I bought my 1983 Montauk last winter I stripped the wood and all the dowels were rotted or broken. They were easily replaced and everything glued back together.
If I were making from scratch I think I would use 1/2 lap joints with epoxy and small screws from the backside. In my case the dowels worked fine until I replaced them 26 years later. If the origional dowels would have been made from teak or cypress or something rot proof I doubt they would have needed replacement. I believe they were just standard hardwood like maple. What ever they were it was a very fine fiber not something course like teak or mahogany.
The glue also wasn't epoxy eithor. I replaced them with oak dowels slathered with epoxy. Drill a 3/16 hole down the remains and then ream out with a 1/4 inch drill. All the old dowel just collapses and cleans out well.
Steve
ConB posted 11-06-2009 10:02 PM ET (US)
Dowels and epoxy will work well. If you are making new frames and have a biscuit joiner, that and epoxy would make a strong joint also.
ConB
westcoastwhaler posted 11-07-2009 07:07 PM ET (US)
Biscuit joints was the original direction I was going, but I may go back to dowel and epoxy. I was also thinking screws but there is so little area to work with. I will probably mock up both out of pine and see which one feels right.

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Author	Topic: Console Door Frame Re-Build Project
westcoastwhaler	posted 11-06-2009 05:57 PM ET (US) My winter project is to build a new set of teak doors and frames for my Outrage '22. I have the originals and plan to duplicate them in teak. The OEM frames are joined with glue and dowels but over time they have become structurally weak and separate a bit at the seams. Also, the doors do not fit flush (I believe this is a hinge issue). I am soliciting ideas about a better method for joining the corners. Any thoughts are welcome.
Stevebaz	posted 11-06-2009 07:04 PM ET (US) When I bought my 1983 Montauk last winter I stripped the wood and all the dowels were rotted or broken. They were easily replaced and everything glued back together. If I were making from scratch I think I would use 1/2 lap joints with epoxy and small screws from the backside. In my case the dowels worked fine until I replaced them 26 years later. If the origional dowels would have been made from teak or cypress or something rot proof I doubt they would have needed replacement. I believe they were just standard hardwood like maple. What ever they were it was a very fine fiber not something course like teak or mahogany. The glue also wasn't epoxy eithor. I replaced them with oak dowels slathered with epoxy. Drill a 3/16 hole down the remains and then ream out with a 1/4 inch drill. All the old dowel just collapses and cleans out well. Steve
ConB	posted 11-06-2009 10:02 PM ET (US) Dowels and epoxy will work well. If you are making new frames and have a biscuit joiner, that and epoxy would make a strong joint also. ConB
westcoastwhaler	posted 11-07-2009 07:07 PM ET (US) Biscuit joints was the original direction I was going, but I may go back to dowel and epoxy. I was also thinking screws but there is so little area to work with. I will probably mock up both out of pine and see which one feels right.