During the summer, screen doors provide the perfect opportunity for a nice breeze to filter through the house without letting the bugs in. During the winter months, if your screen door is considered a "storm door", the cold air will stay outside, allowing your home to stay warm and cozy. If you enjoy making things, rather than buy a screen door from your local home improvement store, why not consider making one. Although the plan is easy, the door is durable.
You first need to purchase or gather all the necessary equipment and supplies. These items would include a tape measure, circular saw, 10 C-clamps, utility knife, a �-inch chisel, square, paintbrush, polyurethane glue, disposable glue brush, 5/4 lumber (1 �-inch frame), 1/4x3/4-inch screen molding, staples, drill, spade bits, staple gun, nail hammer, 1x1 lumber (cleats), 1-inch brads or nails, paint, aluminum insect screen, door hardware.
The easiest way to begin is to purchase or cut the lumber to the width needed for the stiles and rails for the door. Each of the stiles will need to be equal to the full height needed and rails cut to the full door width. Now lay the boards out and label them on the face so they match the face of another one. Next, the lap joints will need to be cut by inserting one or more boards into a jig that is designed to guide the saw. Place the cutting depth to 9/16-inch or half the board's thickness whatever that may be. Begin at one cut line and then make several passes to remove all the materials located between the two cut lines. This process with then be repeated for all the joints of all the boards.
The next step is to assemble the door parts. Once you determine that the pieces fit well, use the polyurethane glue by applying to the joints with the glue brush. Assemble the pieces and then clamp the joints firmly together with the C-clamps, making sure the overall square is correct by measuring the diagonals of the door. Allow the glue to dry completely. Recessing the screen will provide a nice, professional finish. To make a recess, use glue and then nail 3/4x3/4-inch cleats to the framework, with the flush on the inside.
You will need to paint, stain, or varnish the wood surfaces before you install the screen. Once the finish is dry, place the door on blocks or something to get it up off the floor. Clamp the middle of the door and roll the screen over the entire length and width of the door. Starting at the top, staple the screen to the top, then move to the bottom, and secure it there as well. Next, you need to release the clamp and stretch the screen as tight as possible. Move around the outside of the screen, stapling it into place to the stiles and internal frame. Any excess screen will then be cut off with a utility knife and the screen molding cut to size. The molding will then tack it over the screen channel as a way of hiding the staples.
When it comes to choosing hardware for your new screen door, you will find that the options are vast. One of the easiest combinations is a face-mounted spring hinge that has a handle, which is screwed to both the outside and the inside of the door. Once the door is set in the opening, the hinges are attached to the trim around the main door and the screen door stile. Now the handles will be attached with screws. If you want a screen door that locks, a lockset can be installed in place of the spring hinge with handle. Once the hardware is installed, you can enjoy your new screen door.