how to build a shed door out of plywood

shed next to a house
Tools Needed
1 Measuring Tape
2 Drill
3 Drill Bits
4 Screwdriver
5 Screws
6 Door Handle
7 A Helper
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Materials Needed
1 Clamps
2 Circular Saw
3 Sawhorses
4 Pencil
5 Wood Glue
6 L Brackets
7 Hinges
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Total Cost
$25-$75
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Estimated Time
2-3 Hours
Skill Level: Advanced
The total cost and duration may vary when hiring a handyman!

Project Overview

A beautiful large shed in the backyard of a house

Creating a shed door out of plywood involves more than just cutting a piece to size. Without additional support, plywood can buckle and bend, causing it to warp and quickly become useless.

However, that doesn’t mean the process is difficult. All it takes is a bit of extra lumber and some basic tools, and you’ll have a sturdy plywood shed door that will last you for years to come.

Step-By-Step Instructions

1

Take Measurements

person standing in front of a shed doorway

The first step you’ll need to complete is to measure the shed door opening. Use a tape measure to get the height and the width inside the door frame, and then remove a ¼ inch from each measurement to give the door room to open and close.

In most cases, a single sheet of ½ inch plywood will be sufficient for most standard door openings. You’ll also need enough 1 x 4-inch boards to span the width of the door twice and the height of the door minus 8 inches three times.

Along with the wood, you’ll need four L brackets, two or three hinges, and a door handle kit.

2

Cut the Plywood

sheets of plywood

Using your previous measurements, take a tape measure and mark out the necessary cuts on the piece of plywood. Then, using two sawhorses and a circular saw, cut the plywood to the proper size.

After the cuts are complete, take the plywood and measure it in the door opening, verifying that it fits properly. If additional material needs to be removed, remeasure the opening, mark the plywood again, and use the circular saw to make the cuts.

Measure the upper and lower edges of the plywood with a tape measure and record the information. Then, take a board and use a tape measure to mark the measurement associated with the upper edge. Use a straight edge to create a cutting line and use the circular saw to make the cut.

Repeat the process with the lower support using the bottom measurement.

3

Secure the Upper and Lower Supports

person applying wood glue to plywood

Spread wood glue on the back of the upper support board. Carefully place it onto the coordinating end on the plywood, taking care to line up the edges. Then, use wood clamps to hold the board in place. Take wood screws and go through the front of the plywood and into the support board at each corner. Remove the clamps and then add additional screws at 8-inch intervals for additional support.

Repeat the gluing, clamping, and screwing process with the lower board on the bottom edge, making sure the support board is placed on the same face of the plywood as the first.

To get the correct length for the side and center supports, you’ll need to measure the space between the upper and lower supports on both the right and left side edges, as well as the middle. Take a board, measure the proper length for the right side support using a tape measure, and mark the length. Use the straight edge to mark the cutting line and use it to guide the cut with the circular saw. Repeat the process on for the left side and center pieces.

4

Attach the Side and Center Supports

Apply wood glue to the back of the right side support and place it between the upper and lower supports, making sure the edge lines up on the edge of the plywood. Support the board with clamps before securing it with screws, making sure the screws first come through the plywood front and then into the support board. Then, remove the clamps and add additional screws at 8-inch intervals.

Repeat the process on the left side as well as the center support. Place an L bracket at one of the four corners on the side with the supports. Using a drill, add wood screws to secure the bracket. Repeat the process with all four corners.

5

Attach Hinges to the Door

person installing hinges to a door slab

In most cases, the supports will be on the door’s interior surface. That means the hinges will likely be installed on either the right or left side support, depending on which way the door will swing. With the door flat, align the hinges. The exact placement may vary depending on the size of the door and the number of available hinges. However, the upper and lower hinges should always be a minimum of 5 inches from the edge of the door. If there is a third hinge, make sure to center it between the other two.

Once the hinges are placed, use a drill to insert wood screws into the holes, securing the hinges to the door. With assistance from your helper, align the door into the door frame based on the closed position, marking the location of the hinges on the frame with a pencil. Then, move the door into the open position and shift the door until the hinges line up with the previous marks.

Use a drill to insert screws into the door frame to secure the hinges, testing the door swing once they are all in place. The process of installing additional hardware, like a doorknob or handle, may vary depending on the type purchased. Refer to the manufacturer’s installation instructions or an installation guide based on your selection.

Conclusion

Once the above steps are complete, you have a strong, sturdy plywood shed door that will stand the test of time, protecting your items from the elements and giving you an additional sense of privacy.

How To Build A Shed Door Out Of Plywood

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Questions And Answers

Can exterior doors open outwards?

Most entry doors open inward and there is a good reason for this. You don't want the hinge pins exposed on the outside for burglars to be able to easily remove your door. That being said, some doors do open outward it is just not recommended.

How do you frame an exterior door?

This will depend on whether you are making a new opening or using an existing one. This is a project that can be a do-it-yourself project but you should have some home repair knowledge. If you aren't familiar with repair work you can contract someone to do it for you.

What is the Brickmold on an exterior door?

Brickmold can be used on your door or on a casing for a window. It is used for homes and business that have an exterior that is brick. The molding is placed around the window or door and then the brick buts up against the Brickmold providing a finished look.

How do you tell if an exterior door is left or right hand swing?

This process is actually a pretty simple one. Go up to your door and then see which hand is near the knob. If the knob is by your left hand then the door had a left-hand swing. If your right hand is near the knob it is a right-hand swing.

How do you determine the swing of an exterior door?

When your back is against the door’s jamb, your right-hand will be near the knob if it is a right-swing door. Your left-hand will be near the knob if it is a left-swing door.

Can I change the swing of an exterior door?

You will take the hinges off the door. Then, take the latch plate out. Measure hinge mortises height. Mark new hinge mortises height on other side of your door. Put hinges on new hinge mortises. Reattach the door and faceplate.

Can exterior doors swing out?

In all standards, yes, an exterior door could swing out. However, they aren’t made that way because it would be considered a safety issue for your home or business, since the hinges would be exposed.

What is a right hand exterior door?

There are left and right hand exterior doors. The right hand exterior door just means that if your back was facing the door jamb and your right hand was near the doorknob, that would be right-swing or right-hand.

What is a right hand entry exterior door?

A right-hand entry exterior door can be easily explained. Face your back to the door jamb. Is your right-hand near your doorknob? If so, you have a right-hand entry exterior door.

How much is the average exterior door?

The average price of an exterior door can range widely. They can be as low as $150 and as expensive as $2500. The price varies based on different styles, durability, brand and more.

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