How to Build a Dutch Garage Door

Add a little class with a dutch door

A dutch door is a great idea on a garage because it allows the space to be ventilated without letting in curiosity-seekers of the four-footed variety. You can easily make one out of any old exterior door, but if you want to start fresh, use a good quality solid-core door. If you are recycling old hardware, be sure you have an extra set of hinges and a good latch.

Things You'll Need

• Solid-core door
• 4 door hinges
• Chisel
• Drill
• #2 Phillips bit
• 2 sawhorses
• Circular saw
• Goggles
• Straight edge
• Pencil
• Window (optional)
• Jigsaw (optional)
• Router
• 3/8-inch rabbeting bit
• 3/8-inch door trim
• glue
• finish nails
• hammer
• 2-1/4-inch hole saw
• 1-inch drill bit

Instructions

1. Mark four equidistant locations for hinges on the door. Draw the hinge outlines and chisel depressions as deep as the thickness of the hinges. Screw on the hinges.

2. Hang the door so that it swings freely, screwing in all the hinges. Remove the door.

3. Set the door on sawhorses and draw two lines 1/4-inch apart across the center of the door with a straight edge. Cut along both lines with a circular saw.

4. Install a window, if desired, on the upper door. Cut the hole with a jigsaw and drop in the window, securing it to the frame with finish nails. Frame the window with appropriate trim.

5. Use a router to rabbet a 3/8-inch groove on the bottom inside edge of the upper door. Glue a 3/8-inch piece of trim to the top inside edge of the bottom door that will function as a door stop. Allow the glue to dry, then pound in finish nails. Sand the edge of the trim smooth with sandpaper.

6. Hang the bottom door and install the doorknob. Using the template supplied with the knob, drill a 2-1/4-inch hole in the door, and then a 1-inch hole through the edge of the door into the hole you made for the knob. Mount the knob, then chisel out an area on the jamb and install the strike. Install a deadbolt, if desired, in the same way, except you will have to drill a 1-inch hole in the jamb for the bolt. Follow the directions supplied with the knob and deadbolt.

7. Hang the upper half of the door and attach a latch or deadbolt, as desired.

8. Sand the door and apply paint, stain or varnish.

Tips & Warnings

• Apply weatherstripping around the door jamb and between the upper and lower doors for insulation. Install a threshold guard to the bottom door to waterproof it.

• Wear goggles when using a circular saw or a router and follow all safety recommendations. Keep your hands away from spinning blades or router bits.

References

• Country Home: making a dutch door
• Handyman Club: dutch door ideas