The quality of the proposed interior doors, which can be purchased in most construction stores, can not always satisfy buyers. They can be beautiful, attractive, but the strength and durability of these products leaves much to be desired. Therefore, many home masters have no choice but to make interior doors with their own hands. Moreover, there is no big difficulty if you select the material and follow a certain plan.
Materials for the manufacture of cloth
Before starting work on the independent manufacture of the interior door, it is necessary to prepare the material. In most cases, a tree is used for this purpose. The frame of the canvas, as well as the door frame, are made from it.. In addition to wood, can be used:
- Styrofoam;
- Cardboard honeycombs;
- Glass;
- Fiberboard;
- MDF.
Polyfoam and cardboard honeycombs are used as a filler of a door leaf, it is not made of solid wood. These materials are lightweight, which is important for subsequent operation. In addition, the foam allows you to reduce the noise level, making the canvas more sound absorbing.
The use of glass for the manufacture of interior doors is determined primarily by the aesthetic side. Such inserts visually expand the room, and also allow you to diversify the design of the room. Glass also has one more property. It perfectly transmits daylight. Therefore, with glazed interior panels in the corridors of the apartment will be much lighter, even if the door is closed.
Fibreboard or its more advanced version of MDF is used as covering material. In the design of the canvas, these materials are responsible for the decorative finish of the future product. At the same time, MDF is the finishing element, but the fiberboard will have to be further processed to give it an attractive appearance.
In addition to the materials listed, sheets of laminated chipboard can be used as cladding. A wide selection of colors imitating natural wood makes this type of decoration very popular. It should be noted that the use of chipboard will give the doors more rigidity in the diagonals.
As a fixing material, you can use PVA glue or confirmations. To cover the finished canvas will need varnish. If you need to add colors, then the problem is solved thanks to stains and tinted varnishes.
Essential tool
The next stage of preparation will be the preparation of the tool that will be needed for the manufacture of the interior door. At hand you must have:
- Manual or electric planer;
- Hacksaw or electric jigsaw;
- A set of chisels and chisels;
- Manual electric milling cutter;
- Grinding machine;
- Miter box;
- Square and ruler;
- Hammer and mallet;
- Pencil and tape measure.
With this set, you can safely begin the manufacture of any carpentry. You should also prepare a vacuum cleaner to quickly remove not only sawdust, but also dust that should not be on the surface of the product during paintwork.
Manufacturing and assembly
When the preparation ends, then the turn comes to the main work. You will need to perform the following steps step by step:
- Take off dimensions;
- Process material;
- Mark up;
- Saw and assemble the canvas frame;
- Install fittings.
In order for the work to proceed quickly, and the product turned out to be of high quality, it is worth preparing a drawing. Thanks to him, it is easy to markup and not make a mistake with the configuration of the future door.
Web measurement
Work should begin by measuring the doorway.This operation will allow you to calculate the dimensions of the box and the canvas, as well as determine the configuration of the future product. If the opening does not exceed 80 cm, then a single-door door block should be made. With a larger size, you need to make two canvases to reduce the load on the hinges and give a more attractive appearance to the entire product.
The resulting size must be reduced in height and width by 2 cm. This is required to create a mounting joint, obtained between the box bar and the slope of the opening. After installation, it is filled with polyurethane foam. Using the dimensions obtained, a drawing is made, according to which it is necessary to make an interior door.
Such a manual should also contain the dimensions of the door leaf. To calculate them, subtract from the width and height of the opening the thickness of the box beam in the place where a quarter will be selected. From the obtained size it is necessary to subtract another 4 mm in width and from 4 to 12 mm in height. These values fall on the gap, which should remain for the free porch of the door leaf. This determines all the data for the drawing.
It should be noted that the box beam does not have to be made over the entire thickness of the wall. The remaining space can easily close the extension installed after installation.
Making door trim
As soon as the drawing with the dimensions is completely ready, you can proceed to the next stage of work. At this stage, you should process the material and prepare the door leaf frame. To do this, use a planer.
For the frame, you can take a edged board 40 x 100 mm. The ideal option would be to purchase planed material, which will facilitate the work and significantly accelerate it. But you can use just sawn boards. They will have to be processed with a planer to give smoothness. During planing, you should carefully monitor the corners of the bars. They must have a strict angle of 90 degrees. You can check the work using a square.
Next, the marking of parts according to the dimensions indicated in the drawing. On them it will be necessary to saw off the workpiece. If the parts must be secured with spikes, then all horizontal parts of the frame will be longer by the size of two spikes. For example, for bars 100 mm wide, a spike 70 mm long will be required for the connection. In this case, 140 mm should be added to the size of the workpiece, which means two spikes on both sides of the part.
During processing, it is necessary to select a groove or a quarter in the sides of the workpieces. This is necessary for installing glass or inserting panels, if an array of wood was chosen as the door manufacturing option. This work can be done using a manual electric milling cutter. A milling cutter of the corresponding profile is inserted into the tool and selection is made on the side indicated in the diagram.
Details for the door frame must contain a quarter, due to which the door leaf can cover the opening. It is also made a milling machine, setting the depth and width of the sample. The size of the quarter should be based on the thickness of the door leaf. To it you need to add 1 mm for a better vestibule. The depth of the quarter should be at least 10 mm.
Preliminary assembly of a cloth
When the details of the frame are processed and the places for fasteners are sawn down, a preliminary assembly of the door leaf of the interior door can be done with your own hands. This operation will verify the correctness of the markup and filing of all elements. Assemble the structure dry, which means without the use of glue. If you selected the type of connection for confirmations, then you just need to make them without performing a tight twist.
When all the parts are assembled and fastened, check the width and length of the door leaf. If deviations from the drawing are found, then it is necessary to fit the parts. After fine-tuning, the product is again collected and inspected.If all the parameters are met, you can proceed to the next step.
Marking and cutting
Separately, mention should be made of marking parts and making cuts. This is a step-by-step process where the error may result in a rework of the entire product and damaged material. Therefore, all pencil-drawn lines should only be drawn after checking the size. And the markup itself before starting the sawing should be checked with the drawing.
When marking, you can add 1 mm to fit. In this case, even with uneven sawing of the workpiece, it will remain possible to fix this painlessly. If everything works out the first time, then the extra millimeter can simply be removed with a plane. To transfer the drawn line to the other side of the bar, you should take the square and put it right at this point. Since the part has an even angle of 90 degrees, the lines on all sides will exactly repeat the markup made at the very beginning.
If spikes and eyes are chosen as the connection, then you will have to make a complete marking of these elements. The place under the nest should be located exactly in the center. To calculate this data, you just need to divide the thickness of the bar by 2, and then mark the resulting number from any plane of the part. The size of the spike itself should be equal to 1/3 of the thickness of the workpiece. The nest may be half a millimeter smaller than the spike width.
The eye should be carefully drilled strictly according to the marking made, and then cleaned with a chisel. It is impossible to protrude beyond the edges of the lines, otherwise the connection will turn out weakened, and the structure will turn out to be fragile. According to the instructions, it is necessary to precisely adjust the stud connection, so a half-millimeter margin must be left.
Assembly of a cloth and insert of accessories
When all the connections are checked, and the dimensions exactly match those indicated in the drawing, the assembly of the door leaf begins. With a spike connection, it is required to glue the plane of the spikes and the inner surface of the nests with glue. After that, the details are inserted into each other, followed by tamping with a mallet. If this procedure is carried out with a hammer, then a small wooden block should be placed on the padded surface. In this way, damage to the assembled product can be avoided.
After assembly of all parts, no gaps should remain at the joints. If they are, then you should once again knock out this place. An ideal option would be to pull the canvas with vimes. If they are absent, you can install a metal corner on the board, measure the width of the canvas from it, add 3-4 cm to this size and fix another corner. You need three boards that fit the door. A wedge is inserted into the gap between the bar of the canvas and the corner and is knocked out until the gaps completely disappear.
When the door is assembled, a lining is attached to its surface. First, the sheets are cut to the size of the frame and then lay on it. Mounting is done with glue. Additionally, nails can be used. This operation must be carried out carefully and carefully so as not to damage the surface of the cladding, especially if it has a top coat.
Before laying the second sheet on the back of the interior door, the filler is mounted. To do this, the foam or cardboard honeycomb is cut to the size of the free internal space between the parts of the canvas. A tight fit will ensure the integrity of the future door. Next, the second cladding sheet is laid and the canvas gets a finished look.
In order for the door to open, you need to install hinges. They are located at a distance of 20 cm from the edges of the door. Marking is done with a finely sharpened pencil. The nest must be selected with a chisel strictly along the inside of the line, without protruding beyond it. The hinges in the seats must sit without gaps. When the nest is ready and tested, the part is fastened using self-tapping screws or screws included in the kit. Read more about this in the article “Installing the hinges on the door”.
Another element of the interior door is the handle. A lock is often inserted into it, which makes it possible to lock the room if necessary.
The center of the handle should be 1 meter from the floor.. The through hole for the lock is drilled with a drill. The seat is also cleaned with a chisel. After the insertion of the lock is completed, the slots should not remain. Read more about installing the handle in the interior door.
Glass installation in the opening
If the interior door requires glazing, then it is necessary to prepare a glass cutter and select the desired type of glass. This element is inserted into the quarter, which is selected around the entire inner perimeter of the door. Glass is cut 2 mm less than the size of its installation space.
If after working with the glass cutter the sheet has irregularities, they must be removed. To do this, you can use pliers. With a large residue (from 2 mm), another cut line should be drawn. This will allow easier and better removal of the surplus. When the procedure is completed, you need to process the edges of the glass with sandpaper.
Next, the glass is installed in a quarter of the door. Mounting is done with a decorative layout, which is nailed up with small nails. This makes it possible to carry out quick repairs in case of damage to the installed glass.
Interior door trim
The assembled door, if it is not trimmed with laminated particleboard, needs to be finished. They can be of the following types:
- Staining;
- Tinting;
- Lamination
Depending on the type of finish chosen, appropriate operations are required.
Dyeing
Before painting the surface of the door leaf, it is necessary to prepare it. And the first thing to do is completely polish. An electric grinder is ideal for this purpose. The tape for it needs to be taken not too abrasive so that small scratches do not remain on the surface. Work is required in the direction of fiber growth. Perpendicular grinding is allowed only if necessary to level the surface and as a rough one.
If chips or dents remain on the door, they should be puttied. The color of the putty needs to be selected corresponding to the shade of the wood from which the canvas is made. So, during subsequent painting this place will not stand out against the general background. After applying the putty, you need to let it dry and grind again.
Next, you need to clean the surface of dust and only after that proceed with painting. To apply the material, brushes, rollers or spray guns are used. The latter option allows you to perform work quickly and with the lowest paint consumption. There should be no drips on the surface during painting. They need to be removed. To get a quality painted door, you need to apply two or three layers of paint.
Tinting
Unlike painting, door tinting involves the subsequent application of varnish. On the prepared surface you need to apply tinting material, which can serve as:
- Stain;
- Mordant;
- Acrylic paint.
Any type of material will give the tree a new color, leaving the texture open. The stain is applied with a brush, roller or spray gun. If necessary, the procedure is repeated after the material has completely dried.
When the desired shade is achieved, the painting is varnished. To achieve a glossy surface, more than three layers should be applied. Moreover, each stage involves grinding with a fine emery tape. This will remove the raised pile and make the surface smooth.
Lamination
An alternative to paints and varnishes is the use of films and veneers.Gluing these materials is called lamination. For home production, the best option would be a cold gluing method..
The surface of the interior door must be prepared in the same way as in the case of painting or tinting. The film or veneer is cut to the size of the door leaf, making an allowance of up to 3 cm. Then, starting from one edge, the material is glued. If a self-adhesive film is used, then protective paper is gradually removed from it as it is glued to the door surface.
The veneer is applied to the glue, which pre-lubricated the canvas. Smooth the material from the middle to the edges. So it will be easier to remove the air that has fallen under it. If the bubble cannot be expelled, then it can be carefully punctured with a needle. This place must be pressed firmly so that the adhesive layer can connect the surface of the door and the veneer. Excess material at the edges is carefully cut with a knife.