View Full Version : Odd size Interior Door
TommyTrip
Jun 10, 2010, 07:59 AM
I'm finishing my basement and building a wall and door to separate the living area and the laundry room. I want to put a Pocket door there, it is under the Center Bean of the House, so it's a bit low. The door size will be 36x72, besides cutting down a luan door, what else are my options? I wanted to use a Jeld-wen molded door but I think it would look funny if I cut it down. I also didn't want to spend a lot for a custom door.
ballengerb1
Jun 10, 2010, 08:52 AM
I think cutting down a luan door will not be as easy as you might picture, they are hollow and you'd have to add a new filler. Shop around at Lowe's or HD and see what else they have, trim some off the top and some off the bottom so get a better look. A pocket door under a beam will be lower than a normal door because of the track and trolley, maybe a bi-fold would be worth considering.
creahands
Jun 10, 2010, 11:39 AM
When cutting height for door, peel luan off bottom strip, clean off dry glue with chisel and reinstall at bottom of door. Use carpenters glue and clamp together for about 20 minutes. Be sure to wipe excess glue off door exterior before it dries.
If using a pocket door frame, it will lower opening about 3 inches.
Chuck
21boat
Jun 10, 2010, 04:18 PM
Just to add here. The best tools for this is a belt sander and tape.
Remove the top and or bottom rails/plugs in the door if cutting more then 1/2" Today's rails in luan doors are skinner and skinner. Carefully pry rail(s) out.
Remove heavy glue from luan and Belt sand the rails clean of glue. (wear mask) if you want by the book.
That done, before you cut the door duct tape around the door where your cuts are, tape being in center of cut. This stops the Luan face from splintering when cutting.
Re glue rails, after that carefully belt sand a slight bevel at all cut edges. This tightens up the luan cut grain and keeps the face from splintering.
BEFORE you hang the door seal that bottom with primer sealer and paint. Everyone forgets to seal door bottoms. Not doing so causes it swell sucking moisture through the unpainted bottom especially in basements.
P.S. if for some reasons you brake a rail/plug, rip down a piece of treated 2by for new door bottom.
hkstroud
Jun 10, 2010, 07:07 PM
Cut 2 1/4" of the top of a six panel Jen Weld and 5 1/4" of the bottom. It will look OK. Run the cut off top and bottom rails through table saw and cut off skin on each side. Or cut some fir to 1x2" and use that for rails. Using a liberal amount of wood glue and insert new rails in the top and the bottom cavities. Clamp. After glue has dried 30 minutes cut another 1/4" off the top and bottom. This will make top and bottom edges flush.