Door Repair
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Tim Storey



Joined: 30 Mar 2007
Posts: 144
Location: NW Indiana

PostPosted: Sat Oct 26, 2013 5:50 pm    Post subject: Door Repair Reply with quote

After cleaning up old doors and reassembling, I'm not sure what to do about the sometimes large gap between the rail and stile. Interior tight, but exterior with 1/16-1/8 gap (varies on current door given three rail boards). I worry that filling it with putty might cause rot at the joint? Didn't want to use epoxy for the same reason, but it doesn't look good.
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Tim S
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TideWater



Joined: 03 Aug 2014
Posts: 22

PostPosted: Fri Nov 23, 2018 8:59 pm    Post subject: Reply with quote

I know this is a really old question - but here goes: Is there any chance that gap was there originally? I recently made a door myself. It was my first and I had gaps like that from where I failed to cut the tenons evenly on both sides - one cheek was longer than the other.

Another possibility for your situation is that the wood was compressed at the joint through wear and tear or during assembly/dismantling. One option to deal with it is to use a piece of veneer to fill the gap. It'll look better if you can attach it when the door is disassembled but you could still slide it in, glue it, and plane the surface after assembly.
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