I really wanted to build something special but didn't want to spend to much on it. Instead of building a real door I decided on using two pieces of scrap plywood and making a fake door facade.
Step 1: Get stuff together you need
So at this point I’ve decided I’m going to use some 3/4″ scrap plywood and buy some cheap poplar wood to use for the box and the faux door panels. I ended up only buying about 18″ of 1×4 poplar. So my plan of attack is basically very simple:
1. Build a box to fit in my measurements
2. Build door, stuff in box
3. Stuff completed door in attic hole
Step 2: Build a box and make a plywood sandwich
Note: After I got the plywood sandwich put together I used a circular saw to clean up the edges a bit. You'll probably want to do the same eventually anyways to make sure the door has enough clearance to swing freely.
Protip: For the love of god make sure you put plenty of wood glue along the edges you think the hinges will go. That way when you screw the hinge in you won't have to worry about splitting the sandwiched boards. I messed that up and had to drop some screws in to reinforce it. :(
Step 3: Lay out the fake door panels using poplar wood
When I got done with the panels I decided that a little quarter round would really help with the look so I added it in the panels. I ran out of raw wood and had to dip into some pre-painted stuff towards the end so don’t let the white throw you.
Step 4: Hinges of Evil
Step 5: The cool part...adding the skeleton lock
In the end even though cutting off one side made the lock a little crooked everything worked out fine.
Step 6: Damnit...more hinges
Step 7: Painting....yay painting!
Step 8: Shove it in the hole
Step 9: Add door stop trim
I cannot repeat this enough…do not DO NOT go crazy with compressing the weatherstripping. You are building an attic door not a bulwark to contain the ravenous zombie hoards! Otherwise you’ll get all the door trim in and wonder why it takes the force of a hundred He-Men to close it.
Step 10: Almost done just added a little trim
For this part you can feel free to use a disposable foam brush if you want. And if anyone was interested the paint color is "vintage taupe" by Behr. You can feel free to do it anyway you want but a side benefit of painting it to match the wall is that the latex paint seals all the nooks and crannies so I don't have to worry about leaks.
That's it! Hope it gave you some ideas on how to make your own!
update 2/8/2012: I added an update to my personal site talking about why I didn't put insulation and with some pictures of my infrared temp gun measuring the door.