Thursday Doors – Garage Attic Access

Several months ago, I mentioned how I was beginning two “side projects” that had to be completed before a much-needed renovation to our garage could begin. Those projects were new access doors for the garage attic storage and a cabinet-style shed on the side of the garage. Let’s just say that life got in the way of the renovation, but the smaller items will be in-place when we try again next year. At least that’s the plan. Planning is one of those things I don’t get too stressed about these days. I’ve learned that the truly important things are being able to put both cars in the garage during the winter, and being able to get the snow blower out of the shed. I added that last bit because it’s the rationale for some door-making that became a third small project.

Accessing the storage space above the garage had become less important as we grew older, for a few reasons, the most significant being that whatever goes up there had to be carried, by me, up a ladder.

You reach a point where you become reluctant to schlep something heavy up a ladder. My research indicates that point lies between 57 and 60.

I said: “had to be carried…” because that requirement is in the past. I bought a hoist! It’s not quite like having a crane, but it’s as close as I get.

The existing doors on the garage had a few issues: They were ugly. They were hard to open, if you wanted in, but they managed to open themselves when you expected them to stay shut. That happened once while I was traveling, and the editor had to call the police department to come, check for burglars, and re-lock the door. I knew I could make more reliable doors, but I struggled with making pretty doors. Since these doors are on the only wall of the garage that faces the street, pretty seemed to be a worthy goal.

I liked the look of the doors I made for the access to the someday-to-be-second floor of our house, but those aren’t exposed to the weather. I figured that I could modify the design, and cover all the weather-facing stuff with PVC. Once I realized that I wasn’t going to attempt roofing and siding this year, I decided to add a window.

Once the doors and the window were complete, Faith came over to run the hoist and install the door from the inside. I guided it into place from the outside. Eventually, Faith will sandblast Pittsburgh-themed images into the window panes (look for an update, next year).

I wrestle with these posts, because some people like to see the process, and some just like to see the final product. If you want to follow the project, click on the upper (left) photo and start a slide show – the captions will guide you through the project. If you want to skip the details, click on a photo further out, or just look at the gallery.

This post is part of a fun weekly series called Thursday Doors, brought to us by Norm Frampton. You don’t have to build your doors; a picture will do fine. If you don’t have a picture, you can draw them or just tell us about doors you remember. I’ve seen people do all those things and Norm lets them all in. Follow this link to Norm’s place, check out his doors and then look for the blue frog. Click that little tadpole and he will lead you into a world of doors.

I’ll be able to get all the plywood out of this one sheet.

The frame is covered with exterior plywood, which is glued and stapled to the frame.

The doors are ready to be skinned with PVC.

The frames are complete.

Completing a half-lap joint on the PVC trim.

This jig, a trim router and a ‘V-groove’ bit will create the illusion of boards.

The outer surface of the window is PVC Brickmold molding.

PVC expands and contracts a lot. The panel is only glued in the center.

Final assembly of the window

Making the opening for the window.

This photo is for my wife. She loves it when I have to use hand tools.

Testing the alignment of the hinges.

The PVC trim gives the illusion of wood, will never require painting, and is waterproof.

It’s a tiny strip, but it completes the illusion.

For now, the windows are poly-carbonate. Eventually, Faith will etch glass panes.

Getting ready to install the window.

The doors will open from the inside for now, so no outside hardware.

Old doors removed. Opening framed. Hoist ready.

The little air pillow can exert 200-300 pounds of force. It helps to get the door plumb.

The doors will eventually be a little lower, and there will be a soffit on the gable end wall above and across the top.

The window is ready.

The lower doors are complete. Starting to build the window.

Faith will sandblast Pittsburgh-themed images into the glass panes. Hers will look better than mine.

Faith gave me the Steelers hard hat for Christmas. I thought it was overkill, but then I smacked my head on the hoist.