Making Wood Doors

Making your own door can provide a custom touch to your home, but done incorrectly, your door might not fit your doorframe. Additional problems might include a door that doesn't fit your door lock. Also, most doors consist of a hollow-core, so if you attempt to build your own hollow-core door, you could wind up with a flimsy door that could crack or eventually fall apart. Done correctly, your solid-core door will match the necessary dimensions, and it will have a provide optimum strength and sound proofing.

Four 36-inch-by-72-inch 1/4-inch fire-treated panels of plywood
Wood glue
Two 36-inch-by-72-inch-by-1/4-inch veneer panels
Two 2-inch-by-72-inch-by-1/2-inch pieces of veneer trim
Two 2-inch-by-36-inch-by-1/2-inch pieces of veneer trim
Power Drill
Doorknob drill attachment
Table saw
Hand square
Tape measure
Carpenter's pencil
Phillips head screwdriver
Two hinges
Four hinge screws
Putty
Putty knife

Instructions

- 1
  Apply a 1/4-inch bead of wood glue to the front and back surfaces of each fire-treated panel of plywood. Position the glue approximately 2 inches from the edge of the panels.
- 2
  Apply three 1/4-inch lines of glue 10 to 12 inches apart within the border of glue.
- 3
  Clamp the panels of wood together, making sure the edges fit flush against one another. Use the hand square to ensure the edges remain square. Wipe away any glue that seeps out of the cracks, and allow the glue to dry for 24 hours.
- 4
  Trim 1/4 inch of each long edge of the door using the table saw.
- 5
  Apply one circular line of glue around the door face's outer edge and three lines of glue spaced 10 to 12 inches apart within this border.
- 6
  Clamp both veneer panels to the broad surfaces of the door and all four pieces of the trim to the edges of the door using the wood clamps. Make sure that all edges remain flush against one another, and allow the glue 24 hours to dry.
- 7
  Measure the distance from the floor to the center of where your door frame's lock hole will go using the tape measure. The position of the lock hole depends on your preference, but typical heights range from 34 to 36 inches off the floor.
- 8
  Measure the same distance up one long edge of your door, marking a "door lock notch" on the door with the carpenter's pencil.
- 9
  Measure approximately 1 1/4 inches in from the edge of the door.
- 10
  Drill the doorknob hole using the power drill fitted with the doorknob attachment.
- 11
  Fit your doorknob assembly within the doorknob hole, securing it with the Phillips screwdriver and the strike plate screws.
- 12
  Screw the hinges into the edge of the door opposite the door knob using the screwdriver and the hinge screws, positioning them approximately 12 to 16 inches from the top and bottom edges.

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Doors