Table of Contents
- 1Build a playhouse by Les Kenny
- 2Identifying the members
- 3Lumber and materials information
- 4Shopping and Cutting lists
- 5Plans - Footprint and front elevation
- 6Plans - Rear and Side Elevation
- 7Plans - Roof, cuts and angles
- 8Making a wood floor
- 9Making a concrete floor
- 10Making the playhouse wall frames
- 11Making the playhouse roof frame
- 12Putting on the playhouse roof cover
- 13Putting on the playhouse wall cover
- 14Making the door
- 15Making the playhouse door frame
- 16Installing the playhouse door
- 17How to make a playhouse window
- 18Making the window sash
- 19Installing the playhouse window
- 20Playhouse Gable and Soffit
- 21Inside finishing
Making the door
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.
For the door you will need 2200mm (88″) of 50×50 (2×2) dressed/surfaced lumber and 1500mm (60″) of 150×50 (2×6) 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. 150×50 (2×6) cut approximately 490mm (20 1/4″) long to fit between the stiles.
B): Middle rail. 150×50 (2×6) cut approximately 490mm (20 1/4″) long to fit between the stiles.
C): Bottom rail. 150×50 (2×6) cut approximately 490mm (20 1/4″) long to fit between the stiles.
D): Vertical stiles. Two pieces of 50×50 stock 1160mm long (2×2 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.
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.
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.
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.