Shop built – DIY Solid core door



hey guys how's it going so see you right up there that's my kitchen yeah right there that makes a lot of dust and a lot of noise so this week's project I got to build a door for right here so I just recently replaced all the interior doors upstairs in main level what I use are the single panel hollow-core doors which I really like and these helical doors are really practical they're relatively cheap for what they are but in this situation here I need to block out a lot of noise so a solid corridor would be more suited I priced out the material I needed at MDF and I worked out to 55 bucks taxes in about a half sheet a 3/4 inch MDF and I bought a full sheet of 5/8 MDF so let's get started to get started on this project I first took some very careful measurements of the door opening then I went ahead and made a cut list and I ripped all my Stiles and rails to 5 inches except for the bottom rail I'm going to make that 10 inches wide a standard door thickness is inch and 3/8 so to get that thickness I'm going to take a piece of 5/8 and a piece of 3/4 and laminate those together so at this point the project might be wondering why I chose MDF for the material posted something like hardwood or even construction grade material and while hardwood is just too expensive but I did consider construction grade material but what I was mainly worried about is warpage and if you take a look at this 2 by 10 item on the shelf I just bought that about a month ago it was somewhat straight and just sitting there it warped that much and with only a top and bottom rail in this door nothing in between the really supported I was just really worried that it would eventually warp the door because it made such a mess during glue up I couldn't just clean up the edges by running along the fence I had to actually make a little sled to clean up the first edge and then I could use the table saw fence to do the other side here I'm just cutting the rails to final length using my table saw sled and it was time to make a pile of dust I'm going to use my 3/8 inch dado stack to cut a groove along all my Stiles and rails and my mortise is actually going to be 2 inches deep so there's a lot of cutting to do here and I just took my time I went really slow until I got that Center cut all done on all the Stiles and rails so work with MDF it's absolutely crucial that these mortars end up dead center because I'm not going to be able to say anything flush later so I just really took my time here and kind of inched up on it until I got a really nice fit for a 5/8 panel now it's time to cut the Tenon's on all the rails and I just simply did this with my miter gauge and still using my 3/8 inch dado stack well the last thing to do before glue up is just to make the center panel which is cut at a 5/8 MDF I cut the width first and then cut the length using the skill saw Gloop has been pretty simple with my in Vice here I just started out by putting that rail and the vise and then dropping my panel in once I had two panel in it was just a matter of putting glue on all the morcín Tenon's and fitting everything together so I struggled a little bit trying to get that top rail on but it did eventually get it to go once it was all together I just measured corner to corner make sure everything was square so unfortunately I did make a pretty big mistake here you can see the corner was closest to us there's a little bit of a gap there and that's just because I made the tenon too long and at this point it was just too hard to get that rail back off so luckily this is just a painted door and I will be able to fill that in with spackle and you'll probably never ever notice it with the construction of the door complete I decided to put my first coat of primer on but then I realized it was probably a better idea to get the mortise cut for the hinges as well as the hole drilled for the doorknob before I put any of the top coats on I'll just save that for once the doors installed for laying out for the hinges I just make sure I don't forget to add 3/16 of an inch for a gap between the door jamb and the door itself then I'll use a square to set the width of the mortise and this will also act as a reference mark to trace out my hinge you they actually hollow out the motors I just use one of these trim routers with a straight bit installed I do it all freehand and I just take my time go really slow and follow my line as close as possible now look a little bit of practice you'll be surprised how accurate you can do this free end drill a hole for the doorknob sighs got one of these little jig so it makes a lot easier to line up the holes and get the right distance from the edge and all that stuff and I can finally install the door install the hinge halves on the door and the jamb first but one of them wasn't quite lining up so I actually had it just loosen that bottom hinge a little bit and it popped right into place and seemed to fit really well I never mentioned it but I did install a brand new door jamb in here and I'm just installing the doorstop on it there now notice all the dust on those stairs hopefully this door is going to solve that problem well guys all know I'm really happy on the way this turned out and I think it's a really good alternative to buying a solid core door if you liked this project please give me a thumbs up and I'm Ryan Agua thanks for watching

pexels photo 5490755

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