How to Make Bifold Doors

Bifold doors can hide appliances and other unsightly storage spaces.

Often closets and other storage areas are tucked away in unusual places that would otherwise be wasted space. Unfortunately, there often isn't enough space to install a regular door, and yet the items stored in the closet are unsightly or personal in nature. While accordion doors can fit almost any space, they do not suit many styles. In these circumstances, often the best solution is a bifold door. Bifold doors require half the opening distance of normal doors. If you can't find a bifold door suitably sized for your cubbyhole, consider making your own.

Things You'll Need

• Tape measure
• 2 utility doors or shutters
• Saw with fine-toothed blade
• 2 clamps
• Wood glue
• Sandpaper
• 3 piano hinges with screws
• Drill with Phillip's head bit
• Mounting hardware
• Level

Instructions

1. Measure the width and height of the door. Purchase two utility doors that are half the width of the door. A 28-inch opening will require two 14-inch door panels. Your door panels should be 1 to 2 inches shorter than the door frame if you intend to put in a track system. Follow the mounting manufacturer's instructions for proper clearance.

2. Trim both door panels to the same height if it is necessary to reduce the height of the door. You can trim hollow core doors up to 1 inch off the top and the bottom if necessary. Cut the door slowly as the laminated exterior panel of a hollow wood door tends to splinter. If you need to trim the door more than 2 inches, cut it all from one end, remove the lamination from the internal wood core and reinsert the internal wood core into the bottom of the door using wood glue.

3. Trim the width of one of your door panels 1/8 inch to accommodate the hinges. If your doors are wider than the opening, trim up to 1 additional inch on either side, if required. If you are using shutters for your bifold door, trim both sides of each panel about half the distance to maintain the balanced look. Lightly sand exposed, trimmed edges with sandpaper.

4. Join the two door panels, or shutters, with three piano hinges. Attach all three hinges to one panel ensuring that the hinges are plum along the plane of the door edge. Lay the door panels on top of each other on the floor, align all the edges and clamp the doors to each other to prevent them moving out of alignment while you install the hinges. Remove the clamps.

5. Stand the bifold door in its final position and check for proper spacing and that the hinge is folding in the correct direction. If the hinge is not folding properly, turn the door upside down and install it that way. Hold the door level and test the door for ease of opening and closing. If there are problems, check the alignment of the hinges.

6. Install the mounting hardware according to the manufacturer's instructions. Most pin mounting pivots require a hole drilled in top and bottom of the door for the pin and mounting hardware installed at the floor and in the top casing of the doorframe. Some systems include a track, while others allow you to swint the door open freely.

Tips & Warnings

• Instead of buying two utility doors, obtain a solid core door the size of the opening and have it cut in half at a mill.

• If you only need to trim the 1/8 inch required for the hinges, position that trimmed edge towards the frame to improve the appearance.

• All hinges should be at least 3 inches from both the top and bottom edge. This prevents things from catching in the hinges, distributes the weight better and allows for future trimming in case the door swells or you install carpeting or tile and raise the floor level.

• Tie back loose clothing and hair before operating power equipment.

References

• This Old House; How to Install Bifold Doors; Alexandra Bandon
• OSHA: Safeguarding Equipment and Protecting Workers from Amputations

Resources

• Read this Article in Spanish
• Lowes: Install Bifold Doors