An elderly relative whom I help with odd jobs needs a new side door on
his garage as the existing one has rotted away. Unfortunately it's a
non-standard height of 1770 mm. Virtually all doors on sale now seem to
be 1981 mm high, which simply won't fit under the eaves even if the
door-frame were to be cut back.

I know that cheap doors are more or less hollow so you can't cut them
down by much. The options would seem to be (a) get one custom built,
which a quick on-line search suggests will cost £150 or more plus
delivery, or (b) try to build one myself. The existing door is quite
basic: just planks similar to floor-boards braced with thicker boards
behind them in a sort of double Z-shape. But even doing this would
involve rather more wood-cutting than I really feel inclined to do, so I
would be grateful if anyone has any other suggestions.


--
Clive Page

On 20/04/2013 12:58, Clive Page wrote:

I know that cheap doors are more or less hollow so you can't cut them
down by much. The options would seem to be (a) get one custom built,
which a quick on-line search suggests will cost £150 or more plus
delivery, or (b) try to build one myself. The existing door is quite
basic: just planks similar to floor-boards braced with thicker boards
behind them in a sort of double Z-shape. But even doing this would
involve rather more wood-cutting than I really feel inclined to do, so I
would be grateful if anyone has any other suggestions.

If you find a local joiner, I'm sure he ought to be able to make a
cheap'n cheerful door such as you describe for a lot less than that...
it's a very quick task.

--
David

On 20/04/2013 12:58, Clive Page wrote:
An elderly relative whom I help with odd jobs needs a new side door on
his garage as the existing one has rotted away. Unfortunately it's a
non-standard height of 1770 mm. Virtually all doors on sale now seem to
be 1981 mm high, which simply won't fit under the eaves even if the
door-frame were to be cut back.

I know that cheap doors are more or less hollow so you can't cut them
down by much.

Well you can, but you need a bit of appropriate thickness timber to
stick back into the cut edge to restore the frame around the edge.
Having said that, your typical egg box interior door may not last long
exposed to the weather.

The options would seem to be (a) get one custom built,
which a quick on-line search suggests will cost £150 or more plus
delivery, or (b) try to build one myself. The existing door is quite
basic: just planks similar to floor-boards braced with thicker boards
behind them in a sort of double Z-shape. But even doing this would
involve rather more wood-cutting than I really feel inclined to do, so I
would be grateful if anyone has any other suggestions.

b) (what would be called a "ledge and braced door") would not be too bad
if you got most of the timber cut for you. Some timber supply places
will do that for you. They really are pretty simple to make if you buy
some T&G planks for the face, ans some heavier timber for the ledges and
brace.




--
Cheers,

John.

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Most of those non solid doors do not last long as a garage door anyway, but
many years ago I did cut one down, and then found as you say, basically
large corrugated cardboard inside and so I just cut a load of it out and
sank in a bit of wood of the right thickness with plenty of glue.
Good as new.. ahem well.
I think the plank door is not that bad to make, I did a shed one, but you
need to get the Z the right way around to discourage warping
Brian

--
From the Sofa of Brian Gaff Reply address is active
"Clive Page" wrote in message
...
An elderly relative whom I help with odd jobs needs a new side door on his
garage as the existing one has rotted away. Unfortunately it's a
non-standard height of 1770 mm. Virtually all doors on sale now seem to
be 1981 mm high, which simply won't fit under the eaves even if the
door-frame were to be cut back.

I know that cheap doors are more or less hollow so you can't cut them down
by much. The options would seem to be (a) get one custom built, which a
quick on-line search suggests will cost £150 or more plus delivery, or (b)
try to build one myself. The existing door is quite basic: just planks
similar to floor-boards braced with thicker boards behind them in a sort
of double Z-shape. But even doing this would involve rather more
wood-cutting than I really feel inclined to do, so I would be grateful if
anyone has any other suggestions.


--
Clive Page

On Saturday, April 20, 2013 12:58:08 PM UTC+1, Clive Page wrote:

An elderly relative whom I help with odd jobs needs a new side door on
his garage as the existing one has rotted away. Unfortunately it's a
non-standard height of 1770 mm. Virtually all doors on sale now seem to
be 1981 mm high, which simply won't fit under the eaves even if the
door-frame were to be cut back.
I know that cheap doors are more or less hollow so you can't cut them
down by much. The options would seem to be (a) get one custom built,
which a quick on-line search suggests will cost £150 or more plus
delivery, or (b) try to build one myself. The existing door is quite
basic: just planks similar to floor-boards braced with thicker boards
behind them in a sort of double Z-shape. But even doing this would
involve rather more wood-cutting than I really feel inclined to do, so I
would be grateful if anyone has any other suggestions.


I don't think losing 8" would be practical even on doors with lots of small panels. So either make one or pay to have one made. The type you mention are simple enough to make. Just preserve the T&G planks before assembly, or you're liable to fail to get the preservative into the joints.


NT

On 20/04/13 14:32, wrote:
On Saturday, April 20, 2013 12:58:08 PM UTC+1, Clive Page wrote:

An elderly relative whom I help with odd jobs needs a new side door on
his garage as the existing one has rotted away. Unfortunately it's a
non-standard height of 1770 mm. Virtually all doors on sale now seem to
be 1981 mm high, which simply won't fit under the eaves even if the
door-frame were to be cut back.
I know that cheap doors are more or less hollow so you can't cut them
down by much. The options would seem to be (a) get one custom built,
which a quick on-line search suggests will cost £150 or more plus
delivery, or (b) try to build one myself. The existing door is quite
basic: just planks similar to floor-boards braced with thicker boards
behind them in a sort of double Z-shape. But even doing this would
involve rather more wood-cutting than I really feel inclined to do, so I
would be grateful if anyone has any other suggestions.

I don't think losing 8" would be practical even on doors with lots of small panels. So either make one or pay to have one made. The type you mention are simple enough to make. Just preserve the T&G planks before assembly, or you're liable to fail to get the preservative into the joints.


losing 8" is however entirely feasible on a ledge and brace door as
typically there's nowt at the bottom but T &G

However beating £150- whilst possible- may not be worth it in the end.

NT


--
Ineptocracy

(in-ep-toc-ra-cy) €“ a system of government where the least capable to lead are elected by the least capable of producing, and where the members of society least likely to sustain themselves or succeed, are rewarded with goods and services paid for by the confiscated wealth of a diminishing number of producers.

On Sat, 20 Apr 2013 12:58:08 +0100, Clive Page
wrote:

An elderly relative whom I help with odd jobs needs a new side door on
his garage as the existing one has rotted away. Unfortunately it's a
non-standard height of 1770 mm. Virtually all doors on sale now seem to
be 1981 mm high, which simply won't fit under the eaves even if the
door-frame were to be cut back.

I know that cheap doors are more or less hollow so you can't cut them
down by much. The options would seem to be (a) get one custom built,
which a quick on-line search suggests will cost £150 or more plus
delivery, or (b) try to build one myself. The existing door is quite
basic: just planks similar to floor-boards braced with thicker boards
behind them in a sort of double Z-shape. But even doing this would
involve rather more wood-cutting than I really feel inclined to do, so I
would be grateful if anyone has any other suggestions.

The uk.d-i-y wiki has an excellent article about making that kind of
door and breaks the work down into stages so that it doesn't seem too
difficult. Why not have a read through before dismissing the idea of
making it yourself?

http://wiki.diyfaq.org.uk/index.php?...d_brace_do or

Nick

On 20/04/2013 12:58, Clive Page wrote:
An elderly relative whom I help with odd jobs needs a new side door on
his garage as the existing one has rotted away. Unfortunately it's a
non-standard height of 1770 mm. Virtually all doors on sale now seem to
be 1981 mm high, which simply won't fit under the eaves even if the
door-frame were to be cut back.

I know that cheap doors are more or less hollow so you can't cut them
down by much. The options would seem to be (a) get one custom built,
which a quick on-line search suggests will cost £150 or more plus
delivery, or (b) try to build one myself. The existing door is quite
basic: just planks similar to floor-boards braced with thicker boards
behind them in a sort of double Z-shape. But even doing this would
involve rather more wood-cutting than I really feel inclined to do, so I
would be grateful if anyone has any other suggestions.


Have you looked at ledged and braced wooden gates? 1800mm is a common
height and, if one of the widths they are available in is right, it
would not involve a lot of trimming to make it fit.

Colin Bignell

On Saturday, April 20, 2013 12:58:08 PM UTC+1, Clive Page wrote:
An elderly relative whom I help with odd jobs needs a new side door on

his garage as the existing one has rotted away. Unfortunately it's a

non-standard height of 1770 mm. Virtually all doors on sale now seem to

be 1981 mm high, which simply won't fit under the eaves even if the

door-frame were to be cut back.



I know that cheap doors are more or less hollow so you can't cut them

down by much. The options would seem to be (a) get one custom built,

which a quick on-line search suggests will cost £150 or more plus

delivery, or (b) try to build one myself. The existing door is quite

basic: just planks similar to floor-boards braced with thicker boards

behind them in a sort of double Z-shape. But even doing this would

involve rather more wood-cutting than I really feel inclined to do, so I

would be grateful if anyone has any other suggestions.





--

Clive Page

Door blanks are basically solid throughout, so they can be trimmed to any size. Ideally you trim them a bit smaller, and fit hardwood lipping around the edge to finish nicely.

http://www.howdens.com/doors-joinery...k-lightweight/
http://www.howdens.com/doors-joinery...dwood-lipping/
A

On Apr 20, 12:58*pm, Clive Page wrote:
An elderly relative whom I help with odd jobs needs a new side door on
his garage as the existing one has rotted away. *Unfortunately it's a
non-standard height of 1770 mm. *Virtually all doors on sale now seem to
be 1981 mm high, which simply won't fit under the eaves even if the
door-frame were to be cut back.

I know that cheap doors are more or less hollow so you can't cut them
down by much. *The options would seem to be (a) get one custom built,
which a quick on-line search suggests will cost £150 or more plus
delivery, or (b) try to build one myself. *The existing door is quite
basic: just planks similar to floor-boards braced with thicker boards
behind them in a sort of double Z-shape. *But even doing this would
involve rather more wood-cutting than I really feel inclined to do, so I
would be grateful if anyone has any other suggestions.

--
Clive Page

The cheapest door is a ledged and braced door. It will have to be
specially made.
The "hollow" doors are not exterior quality.
Exterior quality doors are solid and can be cut down. The cut edges
have pieces glued on to cover the end grain.
They are very expensive unless you go to an architechtural salvage
place. You might pick one up for £20-£25.

http://en.wikipedia.org/wiki/Door#Le...d_braced_doors

On 20/04/2013 15:29, Nick Odell wrote:
http://wiki.diyfaq.org.uk/index.php?...d_brace_do or

Nick

Thanks, Nick. I hadn't come across that, probably because I didn't know
the right search terms.

--
Clive Page

On 20/04/2013 16:02, Nightjar wrote:
Have you looked at ledged and braced wooden gates? 1800mm is a common
height and, if one of the widths they are available in is right, it
would not involve a lot of trimming to make it fit.

That's a good idea, thanks.


--
Clive Page

Clive Page wrote:
An elderly relative whom I help with odd jobs needs a new side door on
his garage as the existing one has rotted away. Unfortunately it's a
non-standard height of 1770 mm. Virtually all doors on sale now seem
to be 1981 mm high, which simply won't fit under the eaves even if the
door-frame were to be cut back.

I know that cheap doors are more or less hollow so you can't cut them
down by much.

You are talking about internal plywood or pressed board doors here, not
external doors, external doors are solid.

The options would seem to be (a) get one custom built,
which a quick on-line search suggests will cost £150 or more plus
delivery, or (b) try to build one myself. The existing door is quite
basic: just planks similar to floor-boards braced with thicker boards
behind them in a sort of double Z-shape. But even doing this would
involve rather more wood-cutting than I really feel inclined to do,
so I would be grateful if anyone has any other suggestions.

You can get the planks cut to size, lay them down on the ground and cut the
zig-zag shape for bracing out of a few extra planks, there shouldn't be more
than 2 or 3 cuts to perform, nail them all together and hey presto, you've
got a door.

On 20/04/2013 17:58, Clive Page wrote:
On 20/04/2013 15:29, Nick Odell wrote:
http://wiki.diyfaq.org.uk/index.php?...d_brace_do or


Nick

Thanks, Nick. I hadn't come across that, probably because I didn't know
the right search terms.

For a simple gate style door, you can omit the whole frame part -
basically just assemble the facing planks side by side, then fix top,
middle and bottom rails across the back of them. Finally add a couple of
braces. About a 30 minute job.


--
Cheers,

John.

/================================================== ===============\
| Internode Ltd - http://www.internode.co.uk |
|-----------------------------------------------------------------|
| John Rumm - john(at)internode(dot)co(dot)uk |
\================================================= ================/

The Natural Philosopher posted

losing 8" is however entirely feasible on a ledge and brace door as
typically there's nowt at the bottom but T &G

However beating £150- whilst possible- may not be worth it in the end.

You can get ready-made ledge and brace external doors at B&Q online, or
bigger stores, for about £50. All you have to do is trim them to size.

--
Les