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Make a flat door

Rather than using solid wood, which is more expensive and heavier, we used two plywood plates to make this flat door. In addition, we left it up to everyone to decide on the dimensions according to their own needs.

Necessary material

  • square
  • Circular saw
  • Handsaw
  • Mesureing tape
  • Folding Meter
  • Wood wedges
  • Clamps
  • Screwdriver
  • Hammer
  • Drill with depth guide
  • Wood wick
  • Wood scissors
  • Colored pencil
  • Brush
  • Hunting-nails

Steps

  1. Structure
  2. Hinges and lock
  3. Finishing the door

Structure

Taking measurements of the door

Taking measurements of the door

1. The door is made of two plywood plates joined by means of a battens frame. The interior space thus created is filled with glass wool. Four cleats mitered at each of their ends are arranged in reinforcement in each corner, to ensure maximum rigidity.

Saw both panels

Saw both panels

2. For panels of this size, use a circular saw. Both panels must be of perfectly identical measurements. The tracing is therefore important that we guess. They are sawing together. Proceed smoothly, holding the side of the panel with one hand, otherwise breaking

Glue the cleats

Glue the cleats

3. When buying, check the straightness of the cleats. It happens, indeed, that they are deformed. Be careful to avoid any unpleasant surprises. Use cleats of 40 X 40 mm section. Glue the cleats to the vinyl glue.

Tighten the cleat frame

Tighten the cleat frame

4. Arrange the cleats to form a frame on the plywood panel. Hold both elements together with clamps.

Support points of reinforcements

Support points of reinforcements

5. Elements debited in the same material, and cut at 45° on both sides will be arranged in each corner. This cut must be precise to fit perfectly to the cleat of the frame. Determine the support point location of the reinforcements.

Measure the length of the reinforcements

Measure the length of the reinforcements

6. After tracing, measure the distance between the two marks to find the length of the reinforcement.

Nail corner pieces

Nail corner pieces

7. Nail the reinforcement cleats in the frame. They must be perfectly joined.

Inserted cleat for the lock

Inserted cleat for the lock

8. Nail a second cleat to the frame at the future location of the lock.

Set up the second plate

Set up the second plate

9. Before you lay the second plywood sheet, fill the void created by the frame with glass wool. The entire interior of the door is upholstered, not to mention the corners formed by the reinforcement cleats. This glass wool is cut with a simple pair of scissors.

Tighten the whole

Tighten the whole

10. Gently remove the second plate onto the glued frame. Be careful, the glass wool should not exceed. Hold the door firmly using clamps.

Hinges and lock

Determine the place of the hinges

Determine the place of the hinges

11. The hinges consist of two elements: the male part, or hinge, which is embedded in the wall and the female part which is fixed in the edge of the door (here, the cleat). We have sorted here only the female part, the laying of the hinges involving other notions (masonry in particular). The male parts and the female parts must match so that the pivoting of the door can be done.

Hollow out the location of the hinges

Hollow out the location of the hinges

12. Only the hinge supports are recessed. Without this, they would be an obstacle to the proper closing (or opening) of the door. Locate their location on the edge and hollow out with a wood chisel to a thickness corresponding to that of the support of the brass hinge.

Screw the hinge

Screw the hinge

13. When you have checked the installation of the hinge, you can fix it. Screw tight, there must be no play.

Trace the location of the lock

Trace the location of the lock

14. The batten section attached to one of the cleats of the frame is now along the edge opposite that to which the hinges are attached. This doubling was intended to increase the thickness of the cleat in anticipation of the establishment of the lock, being a lock to larder.

Adjust the depth guide

Adjust the depth guide

15. In order to fit the lock, you must pierce the edge of the door. Start by determining the depth required and adjust the depth guide of the drill.

Primer of the mortise

Primer of the mortise

16. Drill several holes side by side by adjusting the depth of cut beforehand. The diameter of the wick corresponds to the width of the space to be excavated.

Finishing the mortise

Finishing the mortise

17. When you have pierced the song along the entire length of the lock, blow up the remaining wood with a chisel.

Location of the headrest

Location of the headrest

18. There are several types of locks, but here being an indoor communication door, a simple lock, extra-flat and cane-beak is enough. Given the structure of our door, an extra flat lock (or mortise) was preferable. Determine the location of the front plate, called the headrest.

Hollow out with a wide chisel

Hollow out with a wide chisel

19. Then dig with a wide wooden chisel so that the headrest fits flush with the edge. The depth of the notch should match the thickness of the faceplate.

drilling

drilling

20. Identify the holes to be drilled for the passage of the key (called "entry barrel") and for that of the rod of the cane. Drill well perpendicular to the mortise

Screwing the headrest

Screwing the headrest

21. Finally, you can finally put the lock in place using the fixing screws after a blank mounting and any corrections you may need to make.

Finishing the door

Second layer of stain

Second layer of stain

22. Now that the door is finished, you can proceed to finishing it. You can paint it or tint it. It is useless to varnish, the wood is not remarkable. We decided to dye it. Choose the shade that will best match your interior. First try shades on plywood scraps.

Nail the rosettes

Nail the rosettes

23. The choice of finishing accessories is very large. You can put rosettes that will give a little style to your door.

Hunt the nail heads

Hunt the nail heads

24. To get a good job, hunt all the nail heads.

Put the handle in place

Put the handle in place

25. The last step is to put the handle in place.

(photos / visuals: © DIY-Prod, except special mention)

On the same topic

  • Questions answers
    • How to renovate a plywood interior door?
  • DIY tips
    • How to make a wooden door for the cellar?
    • Debit the wood and make it a garden gate

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