Having had a busy Friday and Saturday on Sunday I set to work on the door and, as it happened, got more done than I had anticipated. I remembered from the first door that there were a lot of time consuming jobs but this time with the benefit of previous experience I ploughed through it pretty quickly.
I had already stapled the P seal onto the inner MDF panel in the week so it was just a matter of marking out hole positions ensuring they miss any obstructions like locks hinges etc. I then inserted the pins into the door itself and offered up the seal panel and it was in place ready to be screwed on.
I had some concern about the MDF laminations around the lock, even though it was well glued together, there is a very remote chance that the lock could pull through the MDF sheets if enough force was exerted. As extra security measure I inserted some 65mm long screws around the perimeter of the pocket with the lock mechanism sits joining all four layers together.
Next job: fit the surrounding frame door stops. As before, I used MDF cut into 110mm wide lengths to cover the full depth of the frame. Once cut to length I took my time to ensure that they met the door frame stops pretty snug with the door fully closed and marked there position. I repeated the process again to ensure the accuracy as this would be crucial to the effectiveness of the seal. I then moved the frame stops in by 2mm before screwing them in position to ensure that the seal is compressed when closed.
Now I had to get the heavy duty latch fitted. Again, thanks this being the second one I needed very little time to plan. All went well and as before I used the square section barrel to cut the 18 diameter hole for the barrel itself, though this time I mounted it in the drill by inserting a stud length into the threaded end making it a lot easier.
All that remained was to fit the rest of the hardware: the latching plates ensuring that the door was pulled tight compressing, the seals and then the box plate for the lock bolt to engage into. The router again makes light work of this and I quickly had all the fittings in place. So now apart from attaching the plasterboard panel inside and tidying up the outer frame that's doors complete!
What's next? Well, having not really come up with a definite plan for the floor this has been solved. I have been given some light wood effect laminate flooring which had been taken up and replaced by solid wood. Laminate it is. It's in good condition and there's just enough for my needs. I also have a complete new roll of high quality underlay left over from our house extension. So my next major job is laying flooring.