Making Wood Door Panels

Rip the rails and stiles to width per the cut list.

Making wood door panels.

To size an inset door for a specific opening first subtract 1 8 from the size of the opening to allow a 1 16 reveal around the door. Most interior doors today are made from a material called masonite which is a kind of wood fiberboard that is steam cooked and pressure molded onto a thin wood frame to create a slab door that has an appearance of a door with rails stiles and panels. The rail length b equals the door width minus two times the stile width c plus 3 4 for the two 3 8 tenons. Cut 1 by 4 inches 2 5 cm 10 2 cm boards to the height of your door.

If you are planning to stain your door choose lumber and plywood with a similar grain pattern. Take your 1 by 4 inches 2 5 cm 10 2 cm strips of wood and use a circular saw or handsaw to cut them to the height of your door. Items you will need 2 pieces of 48 by 48 by 1 8 inch hardboard old door panel kraft paper if needed masking tape if needed utility knife 8 clamps drill drill bit jigsaw spray adhesive headliner foam fabric stapler. Crosscut them to length leaving them somewhat oversized.

The length of the stiles a equals the door height. I worked on this project for some days i show you how i did all the process. This is what most door. A beautiful exterior wooden door can be built from standard 2 by 6 and 2 by 4 lumber and 1 2 inch plywood.

The door frame is built using loose tenons or dominoes with a panel that floats in a groove in the frame. Cut out 2 pieces of wood for each side of your door and lay them on the floor. Then figure the part sizes as follows. You will trim them flush in.

Clamps clamps and more clamps interior doors are usually 1 3 8 thick. Https ibuildit ca projects plywood door watch how i install this door. How to make the parts of a cabinet door mill the stock to 3 4 thickness for the stiles and rails and to 5 8 thickness for the panel. I build mine by laminating two pieces of 3 4 thick stock.

The benefit of these doors is that they are cheap stable and easy to paint.