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wrote:
TrailRat wrote:
Hi there

After starting a minor repair on my front door i've
discovered the door is made up of plywood sheets and solid
block for the lock mounts. Well somewhere along the line
the solid block has split is starting to force apart the
panels. After closer inspection the door doesn't seem like
it will last much longer or before a swift quick will tear
the door in half.

I can fit a new door easy and can pick one up for about
£100. The question is, would it be easy just to make a new
one. What would be needed to make a 6 panel door(no
glass), what timber, what tools and what skills.

TR

If you are going to use standard lumberyard materials you
will probably have some problems. The material you buy
there is much too green to be completely stable.

But for the sake of looking, find out what the materials
you would need would cost you before starting. If your
door has no features (panels or openings for glass, etc.)
and is smooth, you could build a door out of 2X4s and 1/8"
door skins. Build your frame and attach the pieces to each
other, allowing for the extra area needed to install locks.

When it is as close to square as you can make it, glue/brad
one side of the skins on and make sure it perfectly square.
Then put the other door skin side on and you are ready to
mortise, hang and finish.

However, you should have a flat area and some proficiency
with tools before starting this.

Here's the rub. Doors skins (birch) are about $12. The
doubtful quality 2x4s would be another $15 or so. Brads,
glue, dowels or biscuits would bring you up top about $30
for your cost, and then you would still have not only your
labor to factor, but the fact that the "greener than they
should be 2x4s" may still warp.

Around here (southern US) a solild core birch blank is $56.
Easily worth the other $26 to go down the lumberyard (and
NOT give up a day working on this) and buy the door I want
that is relatively stable and is already beveled correctly
for installation.

Robert

Also, door thicnkesses are not that of a two by four and two
skins. This method may look awkward unless the builder does some
planing beofrehand and matches the thickness ot the seats.

Pop