I am going to be making 3 screen doors for our house. We are in Central Texas and this doors are relatively unprotected (no porch overhang). The last few sets of doors, purchased from the big box stores, have all rotted at the joints after 3-4 years. No matter what I did (multiple coats of paint, caulk in the joints, etc) water would work into those joints and eat up the soft pine.
This time, I am going to try making my own doors either out of Cypress or Cedar (either 4/4 or 5/4 material).
I am wondering about what I should do for joinery?
Pocket holes is the obvious choice, but I was thinking of not painting the doors (sealing only) and the pocket holes would stick out--also not sure how to manufacture plugs out of cedar or cypress.
I am relatively new at fine woodworking, but have done a variety of construction projects and built some shop cabinets. I am willing to learn new skills (and/or buy new tools ), but I am still on the steep side of the learning curve. Any suggestions would be appreciated.
Thanks