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DIY Door System Assembly Instructions

DIY Door System Assembly Instructions & Video

PDF instructions for this Door set are also available.

DIY Door System Recommended Tools
  • Drill Phillips Bit
  • Rubber Mallet
  • Table Saw
  • Square

DIY Door System Parts
  • Left Side Stile QTY: 1
  • Right Side Stile QTY: 1
  • Phillips Screws

DIY Door System Assembly Instructions & Video

FIRST THINGS FIRST

THIS KIT IS AN ENABLER

You have complete creative control over the kind of wood and finish you would like to use in your door. That being said, take into consideration wood thickness and length. The wood you choose should not be more than 3/4” in thickness to fit in the stiles. It is recommended that planks should be tongue and groove for greater strength, but it is not necessary. Also remember that the length will be determined by the size of doorway being covered. We recommend plank widths of no more than three feet to avoid wood warping and damaging the stiles.

NOTE: This DIY kit comes in various sizes. The instructions have been written for the average single door size; but larger doors may need more wood and fastener parts.

NOTE: Always alternate the direction of the wood grain when assembling slats. This will add strength to the assembly and help prevent warpage.

NOTE: The following should be a ‘dry’ assembly. Do not use adhesives in when putting this door together.

Use teamwork - We recommend two people for this build.

1. Select the slat that will be the bottom slat of the door (Figure 1).

NOTE: Ensure the bottom slat is tall enough to accept a 3/4” groove.

2. Using a tape measure and pencil, draw a vertical line on the end of the slat, ensuring the line on the slat is in line with the slot in the metal still (Figure 2).

3. Draw two vertical lines, one on each side of the first line, 3/16” away from the first line (Figure 3). This will show the area to cut away with the table saw.

4. Set the table saw blade to a 3/4” depth (Figure 4).

5. Set the fence to cut just inside one of the outer lines (Figure 4).

6. Run the saw blade through the bottom of the slat, repeating the process and moving the fence until the width of the groove equals 3/8”.

By Definition:

Tongue and Groove Tongue refers to the ridge extending beyond the main portion of the slat. Groove refers to the slot cut into the other side of the slat.

1. On a flat, clean, surface, lay the B3 slat upside down with the groove facing toward the bottom of the door assembly. Lay all B2 slats below B3 with the groove facing toward the bottom. Lay the B1 slat up side down at the bottom of the last B2 slat with the tongue facing toward the top of the door assembly. Assemble by fitting the tongue into the groove of each piece, tapping them together with a rubber mallet (Figure 1).

FOR TONUGE & GROOVE ASSEMBLY

1. On a flat, clean, surface, lay slats upside down with the groove facing toward the bottom of the door assembly. Assemble by fitting the tongue into the groove of each piece, tapping them together with a rubber mallet (Figure 1).

FOR PLANK ASSEMBLY

1. On a flat, clean, surface, lay slats upside down with edges pressed together (Figure 1).

2. Attach stiles (AL and AR) with phillips screws (C) using a drill with a phillips bit to the back of the door (Figure 2).

The door is now ready for a pull installation or to be hung with your selection of hanger.

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