Building a simple screen door can be a great way to let fresh air into your home while keeping bugs and debris out. With some basic tools and materials, you can create a customized screen door to fit any door frame. Follow this step-by-step guide to build your own simple screen door.
Gather the Necessary Materials
Before starting the project, you’ll need to gather the following materials:
- Wood boards – You’ll need wood boards to construct the frame. Pine or poplar boards that are 3/4″ thick work well. Determine the measurements of your door frame and purchase boards accordingly. Leave them long until you’re ready to cut them.
- Screen mesh – Fiberglass or aluminum screen mesh with a tight weave will work best. Make sure you get enough to cover the door opening with extra to attach the screen tautly.
- Screen spline – Screen spline is a flexible plastic cord that fits into the screen frame groove to hold the mesh tautly in place.
- Screen frame corners – These 90 degree metal brackets secure the joints together. Get exterior-grade for durability.
- Staples and staple gun – Stainless steel staples and a staple gun are ideal for assembling the frame. An air compressor can help ensure the staples are secured tightly.
- Hinges – Go for rust-resistant hinges designed for exterior doors. You’ll need at least 2 hinges, likely 3 for a standard sized door.
- Screws – Have an assortment of exterior wood screws on hand. Longer screws will be needed to install the hinges.
- Wood glue – Water-resistant wood glue will create strong joints for the frame.
- Sandpaper – Sandpaper in varying grits will be useful for smoothing and finishing the wood.
- Wood finish – A water-resistant stain, paint or sealer will protect the finished door from the elements.
- Safety gear – Safety glasses, dust mask, work gloves and ear protection are recommended.
Before starting, make sure you have a sturdy work table or sawhorses for the project along with the necessary tools – a circular saw, miter saw, drill/driver, tape measure, clamps, hammer and square. A router with hinge mortising and chamfer bits would also be useful.
Take Precise Measurements
With all your materials and tools now ready, the next step is to measure the door frame opening carefully. This will determine how large your frame boards need to be cut.
Use a tape measure to measure the height and width of the opening at the top, middle and bottom. Write down the measurements – you’ll use the smallest ones. This will account for any out-of-square or uneven areas.
Also measure and note the depth of the door frame from the outside edge to where the screen door will sit. Add at least 1/2″ to allow room for hinge mortises and edge clearances.
Having accurate frame measurements is crucial for building a screen door that fits perfectly within the opening. Take your time and double check all measurements before cutting.
Cut the Frame Boards to Size
With your measurements marked, you can start cutting the frame boards to length using a power miter saw. Clamp a stop block to the saw table at your exact measurement mark for consistency.
Cut two boards to the height of the opening and two boards to the width. The vertical boards are the stiles and the horizontal boards are the rails.
For extra stability, you can make the bottom rail wider than the top rail since it will carry more weight. Cut an additional long board for the screen mesh support brace, which will be installed later.
Work slowly and carefully when cutting to ensure all boards are cut precisely to your measurements. Smooth any rough edges with sandpaper.
Assemble the Frame
The next step is to join the boards together to create the screen door frame using the corner brackets, wood glue and staples. This will take some finesse and muscle.
Apply wood glue to the ends of the boards and clamp them together with corner brackets aligned to make 90 degree angles at each joint. Use a carpenter’s square to check angles.
While aligned, secure brackets in place by hammering staples. Check for square again and add more staples if needed for a super tight joint.
Add wood glue and staples at the joint on the opposite side as well. Use scrap wood strips to tap the brackets tightly into the frame corners.
Allow the glue to cure fully before continuing. Then remove clamps and reinforce joints with additional staples if desired. Check the frame to ensure it’s square.
Attach Hinges to Fit the Door Opening
With the frame assembled, now you can attach the hinges. Place the screen door frame centered in the door opening.
Mark hinge locations on the door jamb. Then mark corresponding locations on the edge of the frame.
Use a hinge mortising kit and chisel to cut shallow recesses in the door edge for hinge cups. Install hinges using long screws into the jamb and frame.
Check door operation and make sure the screen door is aligned properly, closes fully and latches. Add a third hinge at the top if needed for extra support on taller doors.
Add the Screen Mesh
The screen mesh can now be installed into the frame to create the actual barrier. Lay mesh over the frame and cut it several inches larger than the frame on all sides.
Use a router with a chamfer bit to cut a channel along the frame backside for the spline and mesh. Test fit the spline in the routed channel.
Pull the mesh taut across the frame. Press the spline into the channel over the mesh using a spline roller or screwdriver. Cut off any excess spline.
Trim the excess mesh about 1/2″ outside the spline using a sharp utility knife. Check for any rough edges and trim more if needed so the screen sits flush.
Install the Support Brace
For extra stability, a wooden support brace is added under the screen mesh on standard height doors. This prevents sagging over time.
Measure and cut the brace board to fit horizontally between the side stiles, under the bottom rail. Use finish nails or screws to attach into the stiles.
Position the brace to leave a 1/2″ gap under for drainage. Take care not to split the wood when installing the brace.
Apply Protective Finish
Your simple screen door is nearly complete! The last step is to apply a protective wood finish.
A natural oil-based stain is easy to apply and allows the wood grain to show. Multiple coats of water-resistant paint or varnish will provide maximum protection from the elements.
Use 100-150 grit sandpaper to lightly sand the wood. Brush or wipe finish over all surfaces including the brace and corner brackets. Allow drying fully between coats.
Install handle latches and metal screen door catches to finish off your homemade screen door. Enjoy fresh air free of bugs and debris!
Frequently Asked Questions About Building a Simple Screen Door
Building your own screen door is very doable for a motivated DIYer. Here are answers to some common questions on constructing a basic screen door:
What tools do I need to build a screen door?
You’ll need basic woodworking tools like a circular saw, miter saw, jigsaw, drill, hammer, staple gun, square, tape measure, router and safety gear. Useful extras include a hinge mortise kit, air compressor and brad nailer.
What type of wood should I use?
Pine or poplar boards that are straight, knot-free and around 3/4″ thick are ideal. Cedar and redwood are naturally rot-resistant if you can find them. Avoid warped boards.
What kind of screen mesh is best?
Very small woven fiberglass or aluminum mesh will help keep tiny insects out. Look for screen with a tight mesh count of 18×14 or 18×16 per square inch. Get mesh several inches larger than your frame.
How do I attach the screen mesh?
Use screen spline fit into a routed channel around the frame to hold the mesh taut and smooth. A roller tool helps press the flexible spline in evenly.
Do I need a brace for my screen door?
It’s recommended to install a horizontal wood brace on standard height doors to prevent sagging over time. Use a 1×4 board cut to fit snugly between the side frame boards.
How do I hang the screen door?
Exterior rated hinges are best. Mortise the hinge cups into the screen door edge. Install hinge screws into solid wood, not just the screen frame.
What kind of finish should I use?
An oil-based stain or water-resistant exterior paint will protect the wood from weathering. Multiple coats of marine varnish offer maximum protection on cedar or redwood.
Conclusion
Installing a DIY screen door is a satisfying weekend project for any skill level. Following basic steps makes it straightforward to build a custom screen door exactly sized for your doorway with quality construction.
While it requires careful measuring, cutting, assembly and finishing, the ability to have natural airflow without pests is well worth the effort. Your homemade screen door will provide security, beauty and function for years to come.
So don’t settle for an off-the-shelf screen that doesn’t fit right. Make your own simple screen door using these techniques and enjoy fresh air in style!