Was looking around local hardware and lumber stores for rustic wood doors, and seemed no one makes one near us. We recently collected piles of wood from someone's trash in our neighborhood. The frame is a sandwich of 1x5 boards, using pocket screws and glue to join the pieces. Once the frame was made, the inside edges were routered, leaving space to lay the panel boards (which were cut from wood found in the trash.) After the boards were laid into the panels, the two sides were glued together and clamped, holding the panels in place. The doors were then cut to fit the door frames - its an older house so the frames are odd sizes and not perfectly square. I listed this as easy, because most of the time is fitting wood into the panels, sanding, and waiting for glue or stain to dry. The pieces all had stain and polyurethane coats.
Was looking around local hardware and lumber stores for rustic wood doors, and seemed no one makes one near us. We recently collected piles of wood from someone's trash in our neighborhood. The frame is a sandwich of 1x5 boards, using pocket screws and glue to join the pieces. Once the frame was made, the inside edges were routered, leaving space to lay the panel boards (which were cut from wood found in the trash.) After the boards were laid into the panels, the two sides were glued together and clamped, holding the panels in place. The doors were then cut to fit the door frames - its an older house so the frames are odd sizes and not perfectly square. I listed this as easy, because most of the time is fitting wood into the panels, sanding, and waiting for glue or stain to dry. The pieces all had stain and polyurethane coats.
