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Re: [Shop-talk] Odd-shaped door?

To: Doug Braun <>
Subject: Re: [Shop-talk] Odd-shaped door?
From: "Peter J. Thomas" <>
Date: Thu, 14 Jan 2010 22:19:02 -0500
On 1/14/2010 4:28 PM, Doug Braun wrote:
> That's starting to look like the plan.  A local building supply place said 
>that a pre-framed door for a 48" opening could be custom-made, but it would be 
>about $350.
> The harderr part of the project is making a solid, square frame that is 
>properly attached to the cement walls.  I also have to deal with the fact that 
>there is a step where the door is supposed to go, so the sill (if any) might 
>be tricky.
> Doug
You can purchase a frame.  The ones I've seen come as a kit as three 
pieces.  Just plumb the hing side of the frame, hang the door, then fit 
the rest of the frame to the door.

Peter T.

> --- On Thu, 1/14/10, Peter J. Thomas<>  wrote:
>>> Thanks,
>>> Doug
>> You can make a door fairly easily yourself using
>> construction lumber, two sheets of 1/4 luan plywood and some
>> rigid foam.  Cut the two sheets of luan to the size of
>> the door you want.   Lay one sheet down on a
>> flat surface.  Gut and glue lumber to go around the
>> perimeter.  Infill with rigid foam, and finally glue
>> the second sheet of luan on.   This is a
>> stress skin panel door and is the same construction as flat
>> 1970's interior hollow core doors except instead of being
>> filled with corrugated cardboard you're using ridge foam.
>> Peter Thomas
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