[Shop-talk] Odd-shaped door?

[Doug Braun]

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

--- On Thu, 1/14/10, Peter J. Thomas
<pj_thomas at comcast.net> 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