5 Thick (5cm) planks to fit your door frame
Wood glue (lots)
Nails to nail in trim
Screws for hinges
4 Large brass hinges
2 Brass Elephant door handles (or other)
1 Door lock with key (preferably brass)
Black gloss paint
A good primer
Step 2: Glue together 5 large pieces of wood
Cut in the door lock and check position on door frame and cut hole for lock in door frame.
Then out came the circular saw. I measured the door frame to make sure that when I cut this wood to size it would fit, as they say measure twice cut once!
Well you guessed it, it fit like a glove. Being such a large door, and heavy I used 4 large brass hinges to secure it to the door frame. Remember to chisel out the wood for the hinges in the door frame as well as the door.
Step 3: Cut the holes for the glass
We found some really old windows with mullion glass where the frames had almost disintegrated - we bought 4 for 10 bucks each. I butchered one to repair the other three. These were then screwed to the cut outs and I used a moulded trim to finish them off. I stained and varnished the trim. I think the best effect was to turn the mullioned glass sideways instead of the usual upright position.
The pictures here show the door being suspended by large screws I screwed into the door so that when I had painted one side I could simply revolve the door and paint the other side.
Step 4: The finishing touches
We've now been using this door for about 2 and a half years and it still looks and works as well as the first day I put it in.
I will be very happy to answer any questions or offer suggestions to problems you might have with this.