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Widening Double Glazing Rebates for new Windsor Style Door

Postby Emby » Mon Jan 11, 2016 7:58 pm

I have purchased a new Windsor style door (hardwood) to replace my internal front door, which sits inside a porch. I had double glazed units made to fit the ten rebated glazing apertures, but the glazier didn't allow the usual 5mm off the "tight" size and so they are marginally too tight to fit into the apertures. I don't want to waste the DG units (the glazier has refused to replace them but that's another story). I am planning to use a bull-nosed rabbet plane to take 2.5 mm off all around each aperture.
Any comments from an expert on whether this is likely to work and if not, any alternative approach would be most welcome.
I presume there has to be some gap between the wood and the glass to allow for expansion in hot weather, but I am guessing the units will have to be bedded in a thin layer of something, putty?
Any advice gratefully received,
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