Custom 3D Door

Custom 3D Door

Learn how to customize an existing door with a bold chevron-style pattern.


5 col

Difficulty: Intermediate

Materials
Pre-existing standard size door with door handle removed
77” x 34” x 1/8” Lauan plywood (1 1/2” smaller than actual door)
(2) 90” x 1 1/4” x 1/4” wood trim
(4) 35” x 1 1/4” x 1/4” wood trim
(4) 30” x 1 1/4” x 1/4” wood trim
Door handle set
Nail gun 16-gauge with 1” brad nails
Wood glue
Drill with 2 1/8” hole saw bit
Phillips head screwdriver
Exterior enamel eggshell paint & primer in one – base & trim colors of choice
Paint roller
Paintbrush
Paint tray
Tape measure
Ruler
Miter box
Pencil
Handsaw (at least 18” blade)
Safety glasses

Instructions

PREPARING THE LAUAN AND WOOD TRIM:

  1. Use a paint roller to paint one side of the Lauan in the base color of your choice. Use a paintbrush or roller to paint three sides of the wood trim in the trim color of your choice. Allow the paint to dry for at least 2-4 hours before moving on to the next step

ATTACHING THE LAUAN TO THE DOOR:

  1. Lay the Lauan on top of the door with the bottom edge flush with the bottom of the door. There will be a 3/4” inch gap around the Lauan where the door is visible. This space will allow the original door to close without any modifications being made to the door frame (See images below)

  1. A hole will need to be cut in the Lauan to allow a door handle to be attached in later steps. Trace around the existing door handle hole in the door on the underside of the Lauan. Turn the Lauan back over. Using a drill with a 2 1/8” saw bit, drill out the door hole in the Lauan (See images below)

  1. Apply wood glue in lines all over the back of the Lauan. Turn the Lauan back over making sure it’s flush with the bottom of the door. Line up the new hole in the Lauan with the existing hole in the door. Temporarily hold in place with a 12” clamp on each side of the door (See images below)

  1. Put on safety glasses. Secure the Lauan to the door using a nail gun 16-gauge with 1” brad nails spaced every 4”-6” around the edge and across the center (See images below)

ADDING THE TRIM TO THE DOOR:

  1. Lay a piece of 90” x 1 1/4” x 1/4” wood trim diagonally across the Lauan, letting it overhang the top and bottom of the door. Position it so it is 1/2” from the side edges of the Lauan at the top and the bottom. Draw pencil lines across the wood trim where it crosses the Lauan at the top and bottom (See diagram below)

  1. Use a handsaw to cut the wood trim from Step 6 along the pencil lines. Apply a line of wood glue to the back of the wood trim and attach it onto the Lauan, making sure it is still 1/2” from the side edges and flush with the top and bottom edges (See image below)

  1. Put on safety glasses. Secure the wood trim in place using a nail gun 16-gauge with 1” brad nails spaced every 4”-6” along the trim (See image below)

  1. Take the second piece of 90” x 1 1/4” x 1/4” wood trim and center it in the miter box, flush with one side of the box. Eyeballing the center of the wood is fine. Use a saw to cut the wood trim in half at a 45° angle (See image below)
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  1. Take the two pieces of cut wood trim and lay them on the Lauan, either side of the wood trim from Step 7 to make a large X-shape across the door. Repeat Steps 6 to 8 for cutting the ends of the wood trim where they overhang the top and bottom of the door (See images below)

  1. To add the next trim triangle to the door, measure 29” up from the center of the bottom of the door and mark with a pencil. This will be the height of the middle triangle (See diagram below)

  1. Use the miter box to cut a 45° angle in one end of the 35” x 1 1/4” x 1/4” wood trim. Lay the trim on the door with the mitered corner resting on the 29” mark from Step 11 and the untrimmed corner overhanging the end of the door. Measure 3” in from the inside edge of the trim from Step 10 and line up the overhanging trim with the 3” mark. Repeat Steps 6 to 8 for cutting the overhanging trim to fit with the edge of the Lauan and attaching it (See images below)

  1. Measure 3” in from the inside edge of the opposite side of the doorframe and mark with a pencil. To make the triangle, lay 35” x 1 1/4” x 1/4” wood trim on the Lauan with one end overhanging at the 3” mark and the other end overlapping the 29” point of the trim from Step 12. Mark with a pencil the angle at the top and bottom of the 35” x 1 1/4” x 1/4” wood trim where it overlaps the top of the triangle and the door edge. Repeat Steps 6 to 8 for cutting the overhanging trim to fit with the edge of the Lauan, the top point of the triangle and attaching it (See images below)

  1. To add the smallest trim triangle to the door, measure 22” up from the center of the end of the door and mark with a pencil. This will be the height of the smallest triangle (See diagram below)

  1. Repeat Steps 12 and 13 to cut and attach the smallest trim triangle (See images below)

  1. Repeats Steps 11 to 15 for adding 29” and 22” triangles at the opposite end of the door
  1. Paint the edges of the door that is still visible around the Lauan in the same color as the Lauan. Also paint around the door handle hole. Allow the paint to dry for 2-4 hours before moving on to the next step (See images below)

ADDING THE DOOR HANDLE:

  1. Pass the door lever latch through the side hole in the door. Secure in place using a Phillips head screwdriver and (2) 1” wood screws (See images below)

  1. Place a door handle over the door handle hole so the mechanism passes through the door lever latch (See images below)

  1. Attach the second side of the door handle on the other side of the door using a Phillips head screwdriver and the door handle screws

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