BobVila.com

Bob works with the crew from Thorough Construction as they prepare the Woodport door for hanging on site. The door is stabilized by a horse that holds it steady while the work is done. A jig serves as a guide as they router the mortise for each brass ball-bearing hinge. The router creates uniform, flat cuts for the hinges on both the door and the jamb piece. The jambs and header are made from poplar. They are glued and then screwed in place, checked for square, then braced with temporary strapping before being transported to the rough opening. A single screw is set in the header to hold it in place while the installers shim it and check to be sure it is plumb and level. The door jambs and header are then screwed into place. They must trim the door along the bottom edge, which is taped to protect the finish from damage during cutting. Once in place, temporary drywall screws hold the door until the brass screws are inserted as a finish detail when all adjustments have been made.

Bob meets with Ryley and builds a door jig to and a plank door with beadboards. Ryley oultines the door construction process and build the first of seven doors.

Bob meets with Mark Van Sickle from Merillat who is installing hardware on the new semi-custom kitchen cabinets. The Merillat cabinet doors and face frames are solid cherry in a cider finish. The cabinet end panels can be specified by the homeowner or architect to either match the cabinet fronts or to be made of plywood. Mark has set up a drilling jig for drilling holes for hardware to keep all holes on the same 5-inch center. He shows us the contemporary profile stainless steel pulls that will be attached to the doors. This set of cabinets has an unusual setup; it consists of 3 wall cabinets stacked on top of each other and built up on a platform for a toekick. This is an unusual installation creating a whole wall of cabinets like a butler's pantry while saving money buy using standard overhead cabinets. Solid end panels will be added to cover the seams of the stacked cabinets. Bob and Mark move over to the other wall where they notice the orgonomics - the extra organizational features that can be added to cabinetry - including a built-in wastebasket, a pull-out for cooking oils, a sink tray for scouring pads and sponges, an under sink tote for cleaning supplies, and a dishtowel holder. The pantry unit also incorporates orgonomics with slide-out wire baskets that are easy to install and adjustable to different heights - perfect for dry goods, cans, and cereal.

Bob takes a look at the Victorian verge board as it extends from the roof. He reviews the construction of the roof overhang and adding a lead cap. They install the verge board with galvanized nails and review the book they found the design in, �Wood Motifs in American Domestic Architecture� by Ben Karp. Its library of Congress Catalog Number is 66-13771 and was published by Bonanza Books. Riley shows Bob how he created the template for the verge board and how to cut the pattern with a Jig Saw.