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How to make a door

making a shed door




Instructions - Making the door   Page 14 of 21  

How to make a door suitable for a shed or a playhouse.

This particular door is made specifically for a playhouse although a bigger version would also be suitable for a shed or similar type of structure.

Full page contents are at the bottom of the page.

The lumber
For the door you will need 2200mm (88") of 50x50 (2x2) dressed/surfaced lumber and 1500mm (60") of 150x50 (2x6) dressed/surfaced lumber.
NOTE: The actual size of the lumber when dressed finishes smaller than the nominal size stated above so make any necessary allowances.
For more information on lumber sizes click here. Also ensure the lumber that you use is suitable for exterior use.
You will also need a piece of 3mm (1/8") thick acrylic sheet (plastic glass) for the pane, a panel of 12mm (1/2") plywood, some strips of wood for the decorative grille, some glue and 4 pieces of 25mm metal strap.

The door parts, the dimensions and cutting detail.
A): Top rail. 150x50 (2x6) cut approximately 490mm (20 1/4") long to fit between the stiles.
B): Middle rail. 150x50 (2x6) cut approximately 490mm (20 1/4") long to fit between the stiles.
C): Bottom rail. 150x50 (2x6) cut approximately 490mm (20 1/4") long to fit between the stiles.
D): Vertical stiles. Two pieces of 50x50 stock 1160mm long (2x2 stock 46 5/8" long)
E): Acrylic sheet (plastic glass) 3mm (1/8") thick. Cut to suit
F): Plywood panel 12mm (1/2") thick. Cut to suit
G): Muntin bar (grille). In this case it is a strip of wood glued to the pane and is decorative only.

  door terminology

Step 1. Cut and groove the door members
Cut grooves in the members that house the acrylic sheet and the plywood panel. The grooves can be made with a router or by making multiple cuts with a circular saw or bench saw.
A): Top rail. Cut a 12mm deep x12mm wide (1/2" deep x 1/2" wide) groove along the bottom edge.
B): Middle rail. Cut a 12mm deep x12mm wide (1/2" deep x 1/2" wide) groove along the top edge and a 12mm deep x3mm wide (1/2" deep x 1/8" wide) groove along the bottom edge.
C): Bottom rail. Cut a 12mm deep x3mm wide (1/2" deep x 1/8" wide) groove along the top edge.
D): Vertical stiles. Cut a 12mm deep x12mm wide (1/2" deep x 1/2" wide) groove along the portion that houses the plywood and cut a 12mm deep x3mm wide (1/2" deep x 1/8" wide) groove along the portion that houses the acrylic sheet.

  groove the door stiles

Step 2. Assemble the door
2a. Place the door members A, B, C, and D, together without nailing to measure the required sizes of the acrylic sheet and the plywood panel. Make them both 20mm (3/4") bigger than the opening so as to fit into the grooves.

2b. Unassemble the door members and then re-assemble with the acrylic sheet and the plywood panel in place.

Fix by nailing as shown in the illustration and also nail metal straps to the top and the bottom of the door for added strength.

  assemble the door

Step 3. Add the decorative grille
Cut and glue strips of 10mm x 10mm (3/8"x 3/8") wood to the acrylic sheet (plastic glass) making a grid.

This is solely decorative and the size of the wood can vary depending on personal preference.

Use an exterior type glue that will adhere to both wood and plastic.

  the door grille

NOTE: This complete plan-set can also be purchased in downloadable PDF format free of advertising and print friendly for only $5. To purchase click here

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CONTENTS
bullet Page 1:  Introduction and Contents
bullet Page 2:  Identifying the Members - Terminology
bullet Page 3:  Helpful Information
bullet Page 4:  Shopping List and Cutting List
bullet Page 5:  Plans - Footprint and Front Elevation
bullet Page 6:  Plans - Rear Elevation and Side Elevation
bullet Page 7:  Plans - The Roof, Cuts and Angles
bullet Page 8:  Floor - Option 1, Lumber
bullet Page 9:  Floor - Option 2, Concrete
bullet Page 10: Instructions - Wall Frames
bullet Page 11: Instructions - Roof Frame
CONTENTS
bullet Page 12: Instructions - Roof Cover
bullet Page 13: Instructions - Wall Cover
bullet Page 14: Making the Door
bullet Page 15: Making the Door Frame
bullet Page 16: Installing the Door
bullet Page 17: Making the Window Frame
bullet Page 18: Making the Window Sash
bullet Page 19: Installing the Window
bullet Page 20: Instructions - Gable and Soffit
bullet Page 21: Instructions - Inside Finishing




   
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