Woodworking intermediate and carpentry novice seeking some advice:
My neighbor has a 3’X6’4″ door frame that she wants to put a bifold door in. Brosco’s catalog has similar doors, but not quite. If I buy a 6′-8″ door, can I cut it down or is that too much (4 3/4″) to cut off?
I found a bifold door hardware set for $20. Should I try to make my own? If I do make my own, do I A) remove the header and inset the track, B) use frame and panel construction? If I use frame and panel, should I build the door the classic way with mortise and tenons, or could I get away with another technique because the doors are so light (ie biscuit joiner or maybe a frame and panel router set? Should I try MDF for the panels or something else that will finish well but be a bit lighter? What thickness of the door should I go for so it won’t look too flimsy?
Most importantly, what tools can I justify the purchase of to SWMBO for this one project? (I have a router table, table saw, biscuit joiner, and most other stuff – maybe just a frame and panel bit set)
Any and all answers greatly appreciated,
Ben
Replies
I don't know what to tell you if you need a frame and panel set of bifolds. I don't think you could cut that much off of a frame and panel style door. If you can use a hollow core bifold then cut whatever you need to off the bottom and glue a filler piece in the bottom.
FHB's last issue had an article on building doors, take a look at that.
I'm assuming interior door. Have had good luck using 3/4" plywood cut to size, then add 1X4 flat at each side, leave top/bottom as plywood. Have used everythng for both plywood and 1X4s from utility fir to walnut successfully, depending on usage, effect desired.
You are all worried about making the door, I wonder what makes you think the frame is any good. If it is a flush jamb fine, or you can rip the stops; buy a 3-0 kit, trim the top and bottom and install. If the jamb is stopped for a door rip it out and buy a complete unit, you are over what they recommend cutting off height but it isn't impossible to have them set you up a unit to fit your rough frame. If you just must make a door the minimum is about 1 1/8" so you have a chance of the hardware not splitting the door frame, and 1 3'8" is standard door thickness.
As for tools, tell honey you need a new truck to carry materials.
Edited 4/19/2002 3:29:17 PM ET by Qtrmeg
Thanks for the advice. Yes, an interior door. I did see that door-building article - I'll take another look. Frame is flush so I'm ok; I haven't checked it for plumb.
Thanks again,
Ben
Ask at the yard. Not HD but a real lumberyard.
I think a lot of places can get doors at 6'2", 6'6", and 7'0" also pretty easily.
Excellence is its own reward!
I agree with Alan. Use a hollow core, cut off the bottom and glue a filler in.
J. D. Reynolds
Home Improvements
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