Our back patio door is actually one side of a bay window, so it's an odd size and the standard 30" or 36" screen doors available at the home center are too big. Rather than order an expensive custom screen door, I decided to make one myself.
- Southern Yellow Pine 1" x 3.5" x 9' (3 @ $9 each) - Select straight dry boards.
- Window Screen ($5 per roll)
- Vinyl Screen Spline ($3 for a 25' roll)
- 1.5" Kreg screws
- Exterior Paint
- Door handle/latch
- Door closer or spring
- Spline roller tool
Watch my video for details on how I built the screen door. Below are some additional notes about the process, including one thing I may do differently next time.
- I did not plug the pocket holes, in case I need to tighten up the screws after it weathers a while.
- The screen frames covered the pocket holes around the door openings. The pocket holes at the very top and bottom are not that noticeable since I painted inside them.
- The screen doors at Lowe's have the spline grooves cut into the door frame itself. This allows the screen to be attached directly to the door, eliminating the need for screen frames. This is one thing I will do differently next time.
- The screen frame miter joints were not that strong, but I only needed them to stay together long enough to get the frames screwed onto the door.
- The door fit perfectly into the opening, but I did have to chisel out mortises for the hinges to allow the door to open and close a little easier.
Consider this Honey-Do List item CLOSED!
Update: Here is another great method for making a screen door from Tommy at the Shavingwood Workshop. I think I will try Tommy's way of attaching the screen next time.