We used to have this really terrible, tiny bathroom in the middle of what could be a really fantastic large room if it was removed! But that's another story for another time. It had this wide but small window close to the ceiling and as it didn't let in enough sunlight it was decided to enlarge the hole down to the floor. This left a gaping hole in the wall to our courtyard - 2.1 metres by 1.5 metres - which meant we couldn't buy an 'off the shelf' door. So long story short here is the progression of the CASTLE DOOR! (Mysterious music plays).
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 1: Hole in the wall with door frame added
Step 2: Glue together 5 large pieces of wood
The wood were some large planks (3 metres tall by 5 centimetres thick) of pine bought from a timber yard at an horrendous price! These were well glued together with wood glue, clamped and left for a couple of days to dry properly. The planks were sanded with a belt sander to make them smooth and so that you wouldn't see where the seams were.
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.