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.
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.
Cut the 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.
Secure the Upper and Lower Supports
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.
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.
Attach Hinges to the Door
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.
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.