DIY Network

Two Panel Door Shelf Old doors are transformed into shelves. From "From Junky to Funky" episode DFJF-309

In this segment, host Samantha Gleisten uses a pair of narrow doors to create a unique shelving unit for the wall.

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Materials:

old door
wood scraps
primer
paint
coarse and fine grit sandpaper
1/4" plywood
wood putty
wood glue
table saw
circular saw
metal scraper
"T" square
clamps
nail gun
router
palm sander
paint brush/roller

1. Remove all hardware, and then scrape the loose paint from the door surface.

2. Use a palm sander with coarse grit paper to smooth the surface of the door. Fill small imperfections with wood putty and again sand the surface smooth.

3. Square off the ends of the door using a circular saw.

	Figure A
	Figure B
	Figure C

4. Create a router guide (figure A) using wood scraps in order to make a smooth, flat surface for the router to move over the beveled surface of the door.

5. Clamp the guide down, and then use a "T" square to make sure the lines are straight.

6. Route 1/2" x 1/4" deep channels in the door that cut through all three upright frame pieces (figure B). Make the channels every 12 to 15 inches, starting about 1/2 inch up from the bottom.

7. Using a table saw, cut the door in half—creating two full length matching narrow "doors".

8. Cut wood scraps into shelves 11" x 23" using a table saw. Cut another at 11" x 24-1/2" to use as a cap.

9. Cut a 1/4 inch plywood backer using a table saw.

10. Cut square holes out of the doors where the inset panels are using a router (figure C). Sand the cut edges smooth.

11. Finely sand all surfaces, and then apply a coat of primer.

12. Paint the vertical supports and shelves.

13. Assemble the piece on a low table using a nail gun and wood glue. Attach the bottom shelf and top cap first, followed by the remaining shelves. Make sure to apply a thin bead of glue in the shelf channels to hold them firmly in place.

Project Cost:

Door, shelves: Free
Paint, materials: $18

Total: $18