How to Build a Door Out of High Grade Plywood

Measure the inside area of your door frame. Take a few measurements to make sure the door frame is square. Subtract 1/2 inch from the width and height to make a little room for the door to expand. Transfer these measurements to your two sheets of plywood using a straight edge and a pencil. Clamp them and cut them out together using a sharp circular saw.

Lay one board on a flat surface such as the floor. Paint the surface of the plywood with a coating of carpenter’s wood glue using a 3-inch paintbrush. Lay the second board on top and line up the edges so that it fits evenly on all sides. Place several clamps around the end of the plywood sandwich or place a few flat objects on top of it to weight them down. Leave overnight to dry.

Remove the clamps and or weights from the plywood. Place the door in the opening to make sure it fits. Plan on using three butt hinges to hold the door in place since it will be heavy.

Place the hinges on the door in their desired location and mark their location with a pencil. Typically, the top hinge is 8 inches from the top, the bottom is 10 inches from the bottom and the third is in the center. Cut out the recessed spaces using a sharp chisel and hammer. Smooth them out with a piece of 120-grit sandpaper. Place the hinges in the recesses and mark their screw holes. Remove the hinges and drill pilot holes for the screws. Screw the hinges into the door. Place the door in the door frame and hold it up with a few wooden shims until it sits centered. Mark the hinge placements on the door frame. Cut out the recessed area with a chisel and hammer and sand smooth. Install the door frame sections of the hinges.

Install the lockset and doorknob following the directions from the manufacturer. Typically, this involves drilling a hole through the door for the door mechanism and then chiseling out recessed areas for the latching mechanism. Most instructions include a template to use on your door for cutting. Sand the cut areas smooth.

Finish the door with a coat of primer and two coats of exterior-grade paint, using a paint roller. Avoid painting over the chiseled areas. Dry the door between coats according to the manufacturer’s instructions. Sand lightly between coats with 0000-grade steel wool to make sure the layers adhere to each other.

Attach the hardware to the door and hang the door on its hinges. Mark the placement of the latch plate and cut out the recessed area with a chisel. Screw the latch plate in position. Close the door.