Questions? cher@designsbystudioc.com

Build a Screen Door


How to Build a Screen Door

Because my back door opens out, I built a screen door for it long ago. I decided to build another one this time using PVC boards. What are PVC boards you ask? Well, they are just that – “boards” constructed from PVC. They are termite and rot-proof, they can be cut just like wood boards, and they are weather resistant! I found a really great article at The Family Handyman on using PVC boards and sheets. On a side note – I did not know it came in sheets (4′ x 8′) and have been looking for a supplier… I can build all kinds of cool stuff with a PVC sheet! Read on for my tutorial on how to build a screen door…

how to build a screen door 2104

Anyhoo, to custom build a screen door, you’ll need the height and width of the opening minus 1/4″ (for a 1/8″ gap on all sides) from each measurement, and this will give you the finished dimensions of your door. There are many ways to style the lower portion of the screen frame. You can use vertical pieces like I did, horizontal pieces, a “plus” sign, etc.

how to build a screen door

Materials:

  • Lumber or PVC boards to construct the door frame
  • Aluminum screen channel (to make a screen just short of the full length and width of the door)
  • Screen channel corners
  • Spline & Spline tool
  • Screen material
  • Non-mortise hinges

I bought a 1x10x8′ PVC board for $32.00 and ripped two 2-1/2″ “strips” off of it for the sides. I took the remaining piece and cut a 28″ piece to use as the center rail on the door, then ripped the remaining piece to 2-1/2″ for the remaining rails. the leftover piece (which measures approximately 1-3/4″ wide) will be used for the vertical pieces connecting the center and lower rails.

how to build a screen door 2093

how to build a screen door 2095  

I drilled pocket holes in each end of the shorter rail pieces, as well as the vertical pieces for the lower portion of the frame.

how to build a screen door 2096

how to build a screen door 2097  

Assemble the frame using 1-1/4″ pocket hole screws. Regular coarse-thread screws are perfect for the PVC.

how to build a screen door 2098

how to build a screen door 2099    

Once the frame was completely assembled, I robbed the old screen off of the old door but to create a new screen, cut the screen channel approximately 4″ shorter than the height and 4″ narrower than the width of the door. Insert the screen corners to join the channel to each other. Lay the screen material over the frame, and insert the spline using the spline tool. Trim away the excess screen material. Pre-drill holes in the channel and secure the screen frame to the door frame using 1″ screws.

how to build a screen door 2100

how to build a screen door 2101  

Install the hinges and a small handle on each side. Boom! New screen door! Sure beats the “redneck” screen door I used (for one day!)!

how to build a screen door SANY2081

how to build a screen door 2104  

A screen door is very easy to build and I hope my tutorial on how to build a screen door will help get you on your way! Have questions? Contact me at cher {at} designsbystudioc {dot} com!

  • tess

    Oh I wish I could build things! How cool!

    • CherTexter

      You can do it, I swear! Thank you for stopping by!

  • Linda

    Unbelievable!!!! Thanks for showing how. Linda

    • CherTexter

      Thanks so much, Linda! I appreciate it!

  • Pingback: Turn an Old Screen Door into a Chalkboard with Shelves()

Designs by Studio C is your DIY connection to How-To information, DIY projects and free furniture plans. Have questions about the plans? Contact me at cher@designsbystudioc.com!
Some posts on DbSC contain affiliate links. What this means is that if the link is clicked and a sale is made, I will make a small profit. Product links and sponsored posts are what help keep DbSC going - thank you for the support!