In order to increase the energy efficiency of our salvaged wood door we replaced all the single pane glass panels with 1/2" insulated glazing units. When you do this you have to take 3/8" off the trim pieces that hold the glass in. This wouldn't have been a problem if I had the New Yankee Workshop in my back yard.......but I don't. On my table saw there is a 1/2" gap around the blade that grabs little quarter round pieces, chops them up and shoots them out in a million pieces. So we made another jig with some 3/4" plywood. The bottom layer provides a base with a narrow blade opening, the long strip beside the blade serves as a fence and the little square (with 2 black screws) holds the cut piece down so it doesn't fly back and hit me. 
Here are the finished pieces ready to be installed on the door. We had the glazing units sandblasted at Sandblasting Experts over near Norfolk. Apparently they can sandblast anything into a piece of glass. I have lots of ideas now for future projects!!!
The glazing units were set in a bead of glazer's putty before we installed the trim. This will keep the glass from moving around as well as seal up any air leaks. The two wood panels at the bottom of the door were held in place in a similar fashion. Foam insulation has been sandwiched in between the panels to reduce energy loss.
Before we could build the door frame and hang it we had to square off the top and bottom. This old door must have been scraped along a floor for years! The hinge side (at the bottom) was about 5/8" longer than the door knob side.
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