This project was plagued with outside interference from the start. We won the free Therma Tru door and the costs involved with installation. Unfortunately, the installer did not share our vision, wanting to use inferior products and spend time/money updating the rest of the foyer. In the end, he quit and we were able to complete the project the proper way. The only snag now was that Therma Tru required that the door be installed by a certain date. This obliged Wade to spend his (very cold) winter break completing the project using a tent and propane heaters (for our comfort and proper curing of all caulks, glues and silicones used). As Tara was working the midnight shift at the time, she had to spend several days sleeping at a friend's house, leaving Wade to work on the project alone.
The projects starts with alteration/repair of the new door. Our new Therma Tru door and sidelights, touted to be ultra energy efficient, arrived assembled in one piece (exactly as we had requested NOT be done) and there was no insulation in the connecting frame at all. This required us to disassemble it for proper installation.
This is the piece connecting the sidelight and main door. It left us scratching our heads.
Next, we finished the stainable side and painted the exterior. (Pictured is the intermediate stage of staining.)
The tent - is there no end to the usefulness of a compact tractor?
Removal of the old materials
We have a nice limestone sill that needed repair to prevent any leaks under the door
Taking out the old door, it was obvious from where the bulk of Asian beetles and box elder bugs were entering. Insulation will help with that and heat loss.
Framing the hole with the treated lumber that the installer said was not needed
Sidelight #1 installed
Using a router table to make the custom pieces designed to replicate the old design
Our goal was to stick to the original design as much as we could
Our chosen hardware