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How to Replace Handmade Closet Doors

Since you may not be able to find a commercially produced version of a door that was handmade, you may need to replace the door by striving to copy the original as closely as possible. This project requires the careful disassembly of the original door, a potential variety of woodworking skills to create the replacement parts and basic carpentry abilities to install the new door. The tools needed are different for each door, but the basic installation tools required for all doors are the same.

Things You'll Need

  • Drill
  • Drill bits
  • Screwdriver
  • Pry bar or chisel
  • Camera
  • Wood boards
  • Tape measure
  • Saw
  • Medium-grit sandpaper
  • Wood glue
  • Clamps
  • Hammer
  • Stain
  • Brush
  • Sealant
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Instructions

    • 1

      Use a drill or screwdriver to remove the handmade closet door from its hinges, leaving the hinges attached to the closet frame. Remove the doorknob, latch attachments and any other hardware from the door by unscrewing them with a drill or screwdriver. Set the hardware aside.

    • 2

      Dismantle the door using the drill, screwdriver and pry bar when necessary until the door has been fully broken down into its component pieces. Take pictures during the dismantling process to record the location of each piece. Measure and record the dimensions and composition of each piece used in the construction of the door.

    • 3

      Use a tape measure to mark the dimensions of each old board onto a new board and cut out the new board along the markings. Sand each cut edge lightly with medium-grit sandpaper. Attach the boards together in the same manner as the first door. Use glue, nails or screws based on whatever installation method was previously used.

    • 4

      Stain the door to match the original door using a light coat of stain, applied along with the wood grain and given two hours to dry. Repeat the staining until the coat matches the old door when dry. Apply three coats of sealant using the same technique.

    • 5

      Install the hardware into the new door, drilling out holes if necessary for the doorknob, latch, or any other parts requiring a hole. Position the door in place within the frame and against the hinges. Mark the locations of the hinge attachment screws on the new door. Drill out each marking and reposition the door on the hinges. Attach the door to the hinges with the original attachment hardware. Check the operation of the door to make sure it is smooth, and make any adjustments necessary to make it open cleanly.