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I would just buy one. What is the need to make one?? But if you must Materials Needed: 6 pieces of 8-foot 1 x 6 x 3/4 tongue and groove bead-board 40 board feet of 1x 4 x 3/4 lumber for braces and shelf 2 barrel bolt latches 4 door hinges Carpenters glue 1 1/4 wood screws Step 1: The Top and Bottom Door Measure the length and width of the door opening. If possible remove the old door, lay it on the workbench and use it as a pattern. Make the bottom door slightly more than half the door height. Cut bead-board for the top and bottom doors. Also allow space for the shelf to be attached to the bottom door in the overall height measurement. (We found that 6 8-foot pieces of bead-board were just enough for a standard door. Larger doors may require more.) Clamp the boards for the bottom door snugly. Measure the needed width and take half of this measurement off each end board. Rip the end boards to necessary width. In addition, rip two top boards. Glue and clamp the top and bottom assemblies. After the glue has dried, remove from clamps and sand the door assemblies. Step 2: The Shelf Measure and cut a piece of 1 x 4 stock to the door width. Depending on the location of the door such as wide door jams or wall location the ends may need to be cut at an angle. In our case it was between 45-50 degrees. Next mill out a rabbit along the underside back edge of the shelf. This creates a "notch" for mounting the shelf to the top of the bottom door. The width of the lip of the rabbit is the additional space that is added into the overall door height. Screw the shelf to the bottom door. After final fit (check angles after installation) you can remove shelf add glue and re-attach with screws. Step 3: The Braces Cut four pieces of the 1 x 4 stock to the door width. Using glue and screws attach these braces along the top and bottom of the plain side not beadboard side of the doors. Cut two pieces of the 1x 4 stock for the diagonal braces. Glue and screw the diagonal braces in place. Cut four pieces of the 1 x 4 stock for the remaining side braces. Glue and screw in place. Step 4: The Hinges Transfer the hinge locations from the old door or door jam to the top of the top door and the bottom of the bottom door. Use the same distance from the edge for the layout the hinge location for the bottom of the top door and the top of the bottom door. Say that three times fast! Mortise out the door edges for the hinges. Remember to mortise out the door jam for the two "new: hinges also. This is best done by attaching the hinges to the Dutch doors and using the old hinge locations as a reference point. This step can wait until after final finishing. Step 5: The Stain and Finish Give all surfaces a final sanding. Apply the desired stain. Apply 3 coats of polyurethane with a light sanding in between each coat. Step 6: Hang Door Hang the door and adjust the hinges as necessary to ensure easy opening and closing. You've already tested the angle on the shelf, so you should not have any trouble with that now. Step 7: Add the Hardware Once the door is hung in place, attach the desired latch hardware and handles. We used a barrel bolt latch for the bottom door to keep the door closed and a barrel bolt latch to connect the top door to the bottom door. www.bark.addr.com/pat/dutch/dutch.html
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