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How do I build a hollow core door? 39 inches wide, mainly to block the view of the basement from upstairs. Answered

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sandamartinez
sandamartinez

4 months ago

If I substitute pressure treated wood in the same 1x2 dimensions, would I need more cross bars or the same single one to support 0.035” aluminum sheeting (instead of plywood)? I am making weatherproof doors for an outdoor shed. I’m tired of the treated wooden ones rotting , after three sets giving way to the elements.

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ray.rauch
ray.rauch

5 years ago

Having recently done this myself for an oversized hanging closet door it's actually easy and cheap. (with nice results) I bought 2 sheets of hardboard .115 (@ $8/each) and poplar (or pine) 1 3/8 in 8' lengths. These were $1.80/each and you need 5/door depending on width. Cut 2 of them to the width of the door and the remaining 3 to the desired height of the door (subtracting 2 3/4 since the top and bottom pieces sit are respectively above and below the vertical members) Build the rectangular frame from the 5 pieces of 1 3/8x 1 3/8. I used finish nails and glue for strength and laid them out on the flat floor of the garage. Once they are dried run glue along the face of the frame and lay the hardboard on top (mine overlapped because my door was smaller than 4x8' that the hardboard comes in) Once the glue dries on that side use a router with a straight bit with a roller on the bottom to flush trim the hardboard even with the frame. Flip it over and repeat the glue up and when dry the flush trim. The hardboard has a very fine smooth finish that takes paint well and this makes a lightweight and cheap door that is very strong for it's weight. Depending on the width you may need a 4th vertical as the hardboard is quite thin and you don't want it to sag. My closet doors cost about $26 each + paint and hardware. Hanging hardware for my roller doors was ~$7.00 for 2 rollers on top and a plastic guide for the floor. I couldn't find anything that even came close to that price in a custom size and they look great.

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DIY-LiDe
DIY-LiDe

8 years ago

I would buy some 1/4' birch plywood (2 sheets) and some 3/4" pine boards (1X4). Cut the plywood to the size of the needed door. Rip the pine planks down to 1X2 Build the frame to fit the dimensions of the plywood. Put a brace across the door at 12"-16" for support.

With the frame completely assembled, glue the thing together. I would use regular wood glue. You could also use contact cement, but be careful. Pile some books on it and let it sit over night. Sand the edges and you have your door. :)

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paganwonder
paganwonder

11 years ago

Get a pre-hung 36" door and modify opening that it fits in. This is by far the easiest, least specialized skills/tools method. Probably the cheapest in the end as well.