This custom-made patio screen door was made to fit a doorway with unconventional measurements. It’s a non-standard size both in width and height. Fortunately, it is not difficult to make a unique-sized door to fit with some 2x4s and basic tools.
After making this project, I added screening for the summer and vinyl sheeting for low-cost winterizing.
Make a Custom-Size Patio Door
Our covered patio needed a screen door and, after learning how expensive it is to have a custom door made—even for a simple design like this—I decided to build one myself. I am an absolutely amateur woodworker, so if I can make one, you can too.
Due to the odd shape and size of the door opening, the quotes we got were in the hundreds of dollars—just for plain, basic door. Ultimately, my DIY door ended up costing approximately $35. Perfect!
Here are some tips for making your own.
Custom Screen Door Building Plan
Materials & Tools
- I used 2×4 wood lumber. It’s a bulky choice but it also makes a nice, solid door.
- When you measure for the final size of the door and calculate the wood dimensions, note that 2×4″ wood is actually 1.5×3.5″ thick and wide. Sketch the whole thing out first using the final size as your guide. Measure three times, cut once.
- The short reinforcement pieces you see in the lower section of the door are cut with the ends at 45º angles .
- If you’re going to paint or stain the wood, do it before assembly.
- Use wood glue and screws when joining pieces and hold in place with clamps until secure.
- Hardware | You’ll need two handles (one inside, one outside), three hinges, and four steel plates to reinforce the outer corners (fixed in place with 3/4″ wood screws). Also consider whether you’ll want a lock or some sort of latches and plan accordingly.
Here is a look at my door during assembly:
TIPS: Always predrill your screw holes to prevent the wood from splitting.
I recommend using a pocket hole jig for the joins. This way the joins are strong but discrete. I didn’t have this tool when I made this door, but started using one later and they are great.
- Screen or Vinyl | I initially covered my door in mosquito-proof screening but later switched to all-weather clear vinyl to keep rain and wind out of the patio.
As I said, I’m no carpenter but the door works really nicely. I hope the tips help you plan your custom door project.
The photo (above) was taken while I was building the enclosed patio and still using temporary plastic sheeting for the windows. I have since replaced that with screen and vinyl.
To see more details with the vinyl sheeting, see How I Winterized My Covered Patio.
~Melissa the Empress of Dirt ♛