Step 4: Rout the dado

routing the dado, door on sawhorse
Photo: Kindra Clineff
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To seal the door bottom, place the door on sawhorses and use a square to mark out a 5/8-inch-wide dado centered on the door's bottom edge. Tom sets the router's guide so a ½-inch bit will cut next to the top mark when the guide rests on the door's top face. On the first pass, move the router from left to right. On the second pass, the guide rides on the door's opposite side as the router moves from right to left. Make multiple passes to reach full depth (1 inch).
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    Tools List

    • grooving tool
      Grooving tool: can be rented
    • shop vacuum
      Shop vacuum
    • Nut screwdriver
      Small slot-head screwdriver
    • roller spline
      Spline roller
    • router
      Router with edge guide and ½-inch straight bit
    • drill
      Drill/driver
    • hacksaw
      Hacksaw

    Shopping List

    1. WEATHERSTRIPPING

    2. SWEEP