How to Build a Handmade Door

Measure the opening where you want to install your door using a tape measure. Take the measurements of the height, width and depth of the door opening.

Cut four pieces of 1/2-inch high-grade birch plywood the same dimensions as the opening for the door, minus 1/2-inch. This plywood is often used by cabinet makers for its strength and resistance to warping.

Lay one sheet of the high-grade birch plywood on a strong flat surface. Cover the surface with a coating of wood glue, painting it on with a small paint roller to make an even application.

Place the second sheet of plywood over the first, lining up the edges evenly. Cover the surface of the second sheet with the wood glue using the same method as the first. Repeat for the third sheet and then lay the fourth sheet on top.

Lay several flat weights on top of the stack of plywood to act as a clamp as the glue dries. After 30 minutes, scrape away any excess glue oozing from the sides with a putty knife. Leave the wood to dry overnight or for at least eight hours.

Remove the weights and sand the edges of the door with medium grit sandpaper on an electric sander. Once you remove the surface impurities, change to a higher, 120-grit sandpaper to further smooth the edges.

Coat the entire door with an exterior grade finish, one side at a time, allowing the proper drying time before flipping the door to coat the second side. Typically, you want the stain to dry for at least 24 hours. Leave the bottom edge of the door unfinished so the wood can breath. Sand between the three layers of finish with a 0000-grade steel wool to help the layers bond well.

Lay butt hinges on the slab and trace it with a pencil. Use hinges that are rated for the weight of your door. Place the top hinge 8 inches from the top, the bottom hinge 9 inches from the bottom and the middle hinge in the middle. Use a chisel to remove enough wood so the hinge sits flat within the recess. Drill pilot holes for the hinge in the door and screw in place with the hinge screws.

Attach the hinges to the door frame using the previous holes or by centering the door in the opening with a few shims, tracing the outline of the hinges and chiseling out the extra wood. Drill pilot holes and then screw in the hinge screws.

Install the door knob and lock mechanism following the manufacturer’s directions. They usually include templates to hold against the door and detailed instructions for each step.