I was asked to create a stable door for Toby, a ‘tall’ Shetland pony. He was feeling sad due to the fact that he couldn’t see out. Although I would change a few of the build methods, I am still pleased with the outcome.
I began with a simple strip for top and bottom, then complete the door with the twelve-and-a-half, vertical, pieces. I decided that the following was necessary:
- To keep the price down, instead of sticking to the 55mm boarding, I would opt for 47mm, instead. (This fit the frame, perfectly and was a sound choice for a small pony.)
- Fixings would be found, where possible, from stock at the stables.
- I pegged it to make it stronger.
Pegging it was great for strength, but made it hard to construct. Once it was all cut, the holes were bored out and the dowel was added. I used No-More-Nails to create a tough bond. The bottom edge, made a great seal, but the top, was very difficult to attach with the pegs being slightly off on two of them.
The door was then filled in the larger gaps. This helps to create a smoother door for the gloss to cover it.
A few days later, the door was checked in the door frame. Not perfectly square, but fits well.
After planing the edges, I coated it in gloss, twice.
The following week, I fitted the door. Added red hinges and a temporary slide-bolt. There will be a red slide-bolt and kick-over added, in the coming weeks.
All in all, the door has taken just over ten hours to complete, but cost less than half of one from a carpenter.
