We finished off doing the Hallways over the last four days, or rather three days and a morning. We went around putting in liners in almost all of the doorways. We used our 18mm OSB boards to line the left and right edges of the door hole, plus a horizontal piece going over the top. But we wanted to make sure that we finished off with nice square and level sides so when the door is hung, it will swing smoothly and not twist out of alignment. So in order to achieve this, we built a solid frame using some nice straight 89mm thick CLS timber and anchored it all together using lots of triangular plywood pieces to provide a solid perfect rectangle to align to.
Doorway-Framing-jig-1
Doorway-Framing-jig-2
Two of the Bedrooms, number Two and Three were relatively simple to do, putting in 270mm wide pieces of the OSB boards, cut to a height of 2080mm, plus a 876mm wide piece for the top one going over the top. We liberally put a whole load of PU construction glue on all the surfaces inside the door frame and then put in some locking screws to keep it place while the glue dries and cures.
But for Bedroom One, we had to trim and plane the door frame a bit, to get it straightened up. We also inserted additional timber pieces in the utility rail space, all glued on all surfaces, to provide a much stronger load bearing anchorage for the hinge side of the door. We then inserted the OSB liner pieces and got that doorway all square and vertical as well.
The other doorways were the various cupboards and they were only 150mm deep as cupboards do not have the extra layer that forms the Utility and Air Channels and also are only one frame deep instead of two posts. We did the same trick of inserting the extra CLS timber pieces into the utility rail space, again to reinforce the hinges, and slid in the liners as usual.
All these liners are too wide, deliberately so, and we went around trimming the excess off using our router with a ball-bearing straight cutter. If there was too much overlap, we reduced it down first using the jigsaw as it reduced the work load on the router.
Oh yes, we also inserted little pieces in our sliding modules like the Kitchen, Cloakroom and Bathroom, this was also trimmed too.
Some-finished-door-liners-1
Some-finished-door-liners-2
That pretty much completes all the basic structure for all the Hallways downstairs and the only doorways that were not done, was the Linen cupboard and the Entertainment room, and also the Utility room too.
We are going to get on doing the Great Room next, we have decided that we cannot wait for our building insulation foam rejects, we made enquiries again and still no news. But, doing the Great Room, does mean that we will have to move our huge pile of timber upstairs, most of it anyway, ready to start building the upstairs framework and rooms later on. It would be good to see the floor all complete in our Great Room and feel that we are still making progress.