Plywood Shop Doors

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Project by Luke posted 03-19-2012 01:35 AM 2110 views 1 time favorited 5 comments Add to Favorites Watch

We had some residential double doors and really crappy gas closing shocks that were just the pits. I checked around for pricing on commercial doors that look just like these but are normally made of plastic or metal and they are literally thousands of dollars, especially since I needed a double door and a single door. I bought the hinges online, needed nine of them, three for each door. They are spring loaded so that they will swing back and forth. I used 3/4” Plywood to make the actual door, cutting holes for the windows which are .25” Acrylic. The kick plates are .080” brushed aluminum and the push plates are painted white .080” aluminum. All of these materials are leftovers from signs that we have made so we’ll call them freebies. I painted them with a metallic bronze oil base. The double door measures roughly 60×80” and the single measures roughly 36×80. I just left the old frame from the previous doors in place and attached the hinges right to the middle of the stops. Rough cost $450 plus all my labor.

Thanks for looking.

-- LAS,

5 comments so far

View Ken90712's profile (online now)


17683 posts in 3606 days

#1 posted 03-19-2012 02:35 AM

Well done and what a great solution to not wasting money. Not sure I would have thought of the potential savings here. Congrats to you!

-- Ken, "Everyday above ground is a good day!"

View clarkkent's profile


2 posts in 2711 days

#2 posted 03-19-2012 07:59 PM

Hey Luke, The doors look great! Your right those doors you buy at a commercial hardware supplier are expensive.

The one thing I will say so that all the readers know who read this post is the reason they are so expensive is because all of those doors are fire rated doors.

Pretty much every municipality in North America require in their building codes that doors that seperate shop/garage space need to have at least a 2 hour fire rating. Also most require that there is weatherstriping on them as well so that fumes/gasses cannot be transmitted into other occupied spaces. Hence the greater cost and of course the reason most of these doors that are for sale and you see are made from Metal its easier to reach that 2 hour burn barrier with the steel.

-- Failure is success if we learn from it!

View Martyroc's profile


2712 posts in 2723 days

#3 posted 03-19-2012 09:14 PM

Nice doors.

-- Martin ....always count the number of fingers you have before, and after using the saw.

View doncutlip's profile


2832 posts in 3973 days

#4 posted 03-19-2012 10:01 PM

Those turned out great

-- Don, Royersford, PA

View twokidsnosleep's profile


1106 posts in 3391 days

#5 posted 03-21-2012 01:08 AM

Never would have guessed they were not commercial built doors
You did a great job!

-- Scott "Some days you are the big dog, some days you are the fire hydrant"

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