I FINALLY GOT AROUND TO THE DOORS!
I knew these things would be a lot of work. I’m including windows and locks so they need to be done right. I chose to construct them as a wood sandwich, a bit like the walls. Inside each door there is a frame of 1/2″ thick board which will be skinned with 1/4″ luan.
DOUBLING UP THE LUAN
I needed a 1/2″ outer skin for the door (to fit and secure the locks) so I glued another sheet of luan to the existing door skin. I later trimmed the newly attached sheet to match.
INTERIOR DOOR FRAME
The door frame is glued to the skin and provides structure for the lock, hinges, and window. I’ll go back and round off the outer corners with my jigsaw after I finish gluing all the layers together.
The window is held in place by the door-frame.
I’ll fill this space with some triangles, it seems like the right thing to do, even though this will be hidden by the inner and outer skin.
A COMPLETE FRAME
This door frame is done. I’ve added the corner triangles and cut out a space to install the lock. The clamps are holding everything tight while the gorilla glue dries.
KNOTTY PINE DOORS
Instead of luan I decided to skin the inside of the doors with some leftover knotty pine panels. I think the pine panels will look more finished than plywood and tie in nicely with the ceiling.
I traced out the area for the lock and removed it from the frame with a handsaw and a chisel.
READY FOR THE LOCK
The cutout for the lock is a bit rough but should do.
LOCK TEST FIT
The lock fits nicely. A backplate with a handle and deadbolt switch covers this from the inside.
LOCK FROM THE FRONT
The lock fits snugly in the frame and the plastic flange hides the rough cutout.
FLIPPED ONE LOCK
Because the locks are identical one side has to be installed upside down. Fortunately they have no clear top or bottom and, when installed, you can’t see them side-by-side. These locks were not cheap but feel sturdy, have a deadbolt, and are keyed alike.