Make Via Hand

Wooden Door

Overview

This project builds a solid interior wooden door approximately 80 × 200 cm.

The guide focuses on building a strong door frame, fitting panels and installing hinges accurately.

Difficulty: Hard
Estimated Time: 12–20 hours

Materials

  • Hardwood or suitable door timber
  • Door panels
  • Wood glue
  • Hinges
  • Door handle and latch
  • Screws
  • Sandpaper
  • Wood finish

Tools

  • Measuring tape
  • Carpenter’s square
  • Saw
  • Chisels
  • Drill
  • Clamps
  • Router
  • Sander
  • Level

Recommended Dimensions

  • Door width: 80 cm
  • Door height: 200 cm
  • Door thickness: approximately 35–45 mm
  • Panel thickness: approximately 15–20 mm
  • Typical clearance depends on the actual frame
  • Frame corners: 90°

Tips

  • Measure the existing door opening before building the door.
  • Do not assume the opening is perfectly square.
  • Build the door slightly according to the required finished clearance.
  • Use strong hinges appropriate for the door weight.
  • Test-fit the door before applying the finish.

Steps

Step 1 — Measure the Door Opening

Measure the opening at the top, middle and bottom.

Measure the height on both sides.

Record the smallest measurements.

Tip: Old door openings are often not perfectly square. Building to the largest measurement without accounting for the smallest one can result in a door that does not fit.

Step 2 — Plan the Door

Create a drawing showing the stiles, rails and panels.

Use the target size of approximately 80 × 200 cm only if it matches the actual opening.

Tip: Leave the required clearance around the door rather than trying to make the door exactly the same size as the opening.

Step 3 — Prepare the Frame Pieces

Cut the vertical stiles and horizontal rails.

Keep every cut square.

Mark the inside and outside faces.

Tip: Label every component before cutting joinery. This prevents accidentally reversing a piece.

Step 4 — Cut the Joinery

Use suitable mortise-and-tenon or similar strong furniture joints.

Cut the mortises carefully.

Test each tenon individually.

Tip: A furniture joint should fit firmly by hand without requiring excessive force.

Step 5 — Prepare the Panels

Cut the door panels to fit their openings.

If using solid wood, allow room for natural movement.

Do not glue solid panels rigidly into a frame on all sides.

Tip: Leave the appropriate expansion space based on the actual wood and construction method.

Step 6 — Dry Assemble the Door

Assemble the complete door without glue.

Check:

  • Overall dimensions
  • Diagonals
  • Panel fit
  • Square corners

Tip: This is the last easy opportunity to correct the design before glue makes the structure permanent.

Step 7 — Glue the Door

Apply glue to the structural joints.

Assemble the frame.

Clamp it.

Measure the diagonals again.

Allow the glue to cure.

Tip: Use clamps gradually from multiple directions rather than applying extreme pressure from one side.

Step 8 — Fit the Hinges

Mark hinge positions.

For a heavy door, use appropriately rated hinges and distribute them according to the hardware manufacturer’s recommendations.

Recess the hinges carefully if required.

Tip: Test the hinge depth using scrap wood first.

Step 9 — Sand and Finish

Sand progressively from 120 to 220 grit.

Move the door into a clean, dry and well-ventilated room for finishing.

Apply thin coats.

Tip: Finish all accessible surfaces consistently to reduce uneven moisture absorption.

Step 10 — Final Installation

Install the door temporarily.

Check the swing.

Check the gaps.

Install the latch and handle.

Adjust the hinges if necessary.

Tip: Never force the door closed during the first test. Find the exact point of interference and correct it.