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The outer sill rail is largely supported by wooden gussets. One of the gussets in this photo has broken along the grain. A diagonal grain might be a better design.
The above and below photos show new parts for the outer sill assembly. I made the outer sill rail a bit thicker than the original. The original was about 19mm square section (but varied considerably along its length). This seemed quite flimsy, so I increased it to 25mm square section, which more than doubles its bending strength. It also makes it stiffer, which is useful when hammering panel pins into it. The darker wood colour for the door step and sillboard, is mahogany.
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Outer sill
The outer sill rail is largely supported by wooden gussets. One of the gussets in this photo has broken along the grain. A diagonal grain might be a better design.
The above and below photos show new parts for the outer sill assembly. I made the outer sill rail a bit thicker than the original. The original was about 19mm square section (but varied considerably along its length). This seemed quite flimsy, so I increased it to 25mm square section, which more than doubles its bending strength. It also makes it stiffer, which is useful when hammering panel pins into it. The darker wood colour for the door step and sillboard, is mahogany.
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