1. Get Started: Build, Paint and Hang
Before building the door, measure the doorway.
2. Cut Wood Pieces
Cut proper boards to make the outer frame of the door.
3. Frame It
Use the other two proper pieces of wood to make the horizontal supports in the interior frame.
4. Plan for the Handle
Mount a proper piece of wood on either side of the frame at the height you would like your door handle to be.
5. When You're Finished
Here's what your frame should look like after you've built the frame and installed additional supports.
6. Attach Plywood and Insulate
Attach the plywood sheet to the back of the door. Apply wood glue on all top surfaces of the pieces of both your inner and outer frames.
7. Paint It
Use spackle to fill in the screw holes. Lightly sand to ensure your entire surface is smooth and ready for paint.
8. Install Hardware
Measure 6" in from either end of the bottom of the door to attach rolling casters.
9. Hang It
Installing the hardware is best accomplished with the help of a buddy.