Weatherproofing A Door

Tools:

tape measure
chalk line
safety glasses
combination square
jigsaw
clamps
file
wire brush
power drill
nut driver
Lucite-Tuf high-impact acrylic sheet
self-tapping zinc sheet metal screws

1. Measure height and width of door. Transfer measurements to plastic sheets, and use the chalk line to mark nice, straight cut lines (figure A).

2. Take a jigsaw and cut the plastic sheets (figure B). Use a fine-toothed blade on the jigsaw, and set it to cut at a slow speed. If it cuts too fast, the plastic could melt and fuse itself back together.

3. Smooth cut edges with the file and clean the file often with the wire brush to prevent it from clogging.

4. Measure opening for the lock panel, transfer measurements to the plastic sheet and use the jigsaw to cut out the opening. Make two triangular cuts to remove the rectangular area.

5. Fit plastic panel on door and use the clamps to hold it in place (figure C). Prop plastic sheets to the proper height with pieces of cardboard (figure D).

6. Drill pilot holes for screws through plastic and gate, then use the nut driver to install self-tapping screws. Remove protective paper coverings from plastic sheets.