Garage Door Makeover

Kestrel Tongue & Groove Doors are an old world style hand built using old world joinery methods. The aluminium tongue and groove range replicates the traditional style of a wooden tongue and groove door, resulting in a modern stylish door, without the inherent shortcomings of a timber panel. Add the hinges to the horizontal braces on the doors and then ‘hang’ the doors in place by fastening the loose ends of the hinges to the trim surrounding the door opening (see picture at the top of the page).

Timber tongue and groove boarding or wood tongue and groove boarding can be used for multiple applications from wood wall panelling to ceiling boarding. Back at the shop we ripped the tongue and groove off of the cedar boards and used the cedar boards for our door styles and rails. Salvaged vintage DIY sliding barn door glass windows- LOVE the idea- great for the living room- can be closed or open as needed!

I also knew I had a bad case of sticker shock after shopping for a carriage house-style overhead door. Some will build their doors or panels around ¼” oversize in both length and width so that they can take light trim cuts on all four sides to confirm them being square and to get very clean edges. This showed me how the reveal at the end of the rail intersected with the door casing’s site lines, exactly where I needed to position the rail and door stop (an L-bracket bolted to the rail), and how my ideal door width of 34-3/4 inches all worked in unison without building or installing anything.

Because there are many different boards in its design, batten doors are extremely stable doors. If the opening is wide, you might need a pair of doors that swing open from each side of the doorway. Make: is the voice of the Maker Movement, empowering, inspiring, and connecting Makers worldwide to tinker and hack. A DIY interior door project begins with an assessment of one’s tastes and opportunities – not every style found below will suit you or your home.

We built and installed one as the finishing touch of a kitchen remodel and we love it. And, I can tell that it’s not the last place we’ll use this idea. Prince Charming did end up putting a screw at either end of the track so the door can’t accidentally be slid off. Use the clamp bars like winding sticks to help you look for twist in the door frame. NOTE: Make the second door a mirror image of the first, that means that the top 45° corner on the second door will be opposite to that of the first. With both parts of the door hanging, we could now check that all the gaps were not only even, but remained so when the door was opened.

I guess you could rip that off and put a new one further back so that the door didn’t stand proud of the door architrave but it would be a lot of hassle. Which left us the option to see how one cut door and one uncut door fit in each opening. Step 4: The cleanest, safest way to mill the tongue is to rout away the waste a little at a time and not with a couple of heavy passes.


The Alyn pictured are the usual 50/50 equally split doors (both doors the same size), however if you want one door bigger than the other then we can manufacture them for you. I calculate the rail length as follows: Door width minus 2x stile width plus 2x depth of panel groove. In other words, if the stock is warped or twisted the completed door will never fit the opening properly. The window was framed using hardwood beads that were bevelled on both edges so that they’d shed water; the strips on the outside of the door overlap the hole in the boarding by 9mm (3/8in ) all round to form the rebate that supports the glass. Open the barn doors for an entertainment center and close them for a book shelf.

An alternative approach to planking is to forgo cutting the rebate, and making all the door rails the same thickness as the stiles. Make three marks on the ledges in a triangle shape – with the top screw hole centered – for each vertical piece. Once that part was down we had to spend even more time practicing the perfect cut for the tongue on the end to be able to piece the frame together. However, after talking it over with my husband he thought using a running board like some of the other DIY doors out there would provide a better solution, look nicer and also double as a spacer.

All that is left to do on the rear of the door is to give the ledges a quick orbital sand, along with the braces. A bare-faced tongue was machined around the outside edges of the boarding using a rebate block for the sides, and the crosscut saw for the top ends. The door is then lifted up and placed onto the tracking to make it operational and slide friendly!

Step 3: Lower the bit as you would when using a rabbeting bit or slot-cutter, and follow that same cutting process, raising the cutting height a little at a time until the tongue is just a bit thicker than its groove (see Photo 10). The door handles need placing properly, then I need to take the doors down again, punch down a hundred panel pins, fill the holes, treat the knots and paint the doors. Starting with the top ledge, fix a screw through a pre-drilled hole at each end of the ledge – this instantly braces the top of the door. Step 5: When the tongue nearly fits the slot, use the grooved workpiece to dial in the final bit height.

The doors are constructed using aluminium panels that are clipped together and held in place by a moulding, resulting in an incredibly strong door that will resist warping or twisting. An oak ledged door kit would usually take him between 25 and 30 minutes to complete – you may wish to allow a little longer! Chances are the groove is still too narrow at this point so we need to widen the groove.

You can alter these dimensions somewhat if you like but more often than not those changes will be small to get a door with pleasing looks. Note: Also, just because it could be a factor I would put a level on your floor and make sure your floors are level. We’re traditionalists a heart here at Peak Oak and the traditional way to build an oak ledged door was without braces. The Composite Door is a hardwearing maintenance free timber grain effect door, and comes in a range of colours and glass designs.

Make a second door the same as the first by repeating steps two-thru-six and use fig.1 for reference. Also you need a wide flat door frame to accommodate the T hinges or you might have to cut into your frame. Use the grooved workpiece to adjust the bit for the last passes that bring the tongue to final size (see Photo 4). I’ve done three doors this way recently and they have all been easy to make and are in my mind excellent. A yellow sliding barn door and arched doorway are unique features of this bedroom.

Scroll down for inspiration and to find out how to make interior doors and how to make plank doors for your home. First off, let’s get some basic terminology down by looking at a smaller version of the same concept: A cabinet door. They come in different thicknesses and you pop them in around your door trying to make sure that the gap around the door is equal on every side.