Step 1

Step 1: Select Proper Doors

Step 1: Select Proper Doors

Photo by: Image courtesy of Brian Patrick Flynn

Image courtesy of Brian Patrick Flynn

Select Proper Doors

In order to resist the elements, solid-wood doors need to be used for this project; however, the two doors can vary in heights and finishes as long as they have the same width. In order to ensure a level installation, both doors must stand at exactly the same height. Heights can be easily adjusted by using a measuring tape and a pencil to mark the doors to size, then cutting the doors to the exact same height using a circular saw.

Step 2

Cut Side Panels

In order to make the arbor open and airy, cut out the top panels of the doors. Doors with recessed panels simply require cutting around the inside edge of the paneling using a circular saw. When using solid wood doors without paneling, measure and mark the intended opening size with measuring tape and pencil, then cut with circular saw.

Standard exterior entry doors are 36 inches wide. An excellent size for the opening, based on proper scale and proportion of two doors placed across from one another, is 24 inches, leaving approximately six inches of door on each side of the opening.

Step 3

Attach Decorative Edge

Measure and mark the opening of the newly cut door directly to the strip of 1x3 x 6’ lumber, allowing enough space for a one-inch overhang on both sides to accommodate a decorative ledge.

Use a hand saw to cut the strip, then place it along the bottom of the door opening. Secure the ledge into place using wood glue, nails and a hammer. 

For a more decorative look, add pressure-treated crown molding under ledge.

Step 4

Step 4: Reinforce with Rebar

Step 4: Reinforce with Rebar

Photo by: Image courtesy of Brian Patrick Flynn

Image courtesy of Brian Patrick Flynn

Reinforce With Rebar

On the bottom of each door, drill a 1/2” hole that is six inches deep and four inches from each side. Next, hammer a 12” piece of rebar into each drilled hole.

Step 5

Step 5: Determine the Arbor Width

Step 5: Determine the Arbor Width

Photo by: Image courtesy of Brian Patrick Flynn

Image courtesy of Brian Patrick Flynn

Determine Arbor Width

Determine exact distance that the two doors will be spaced apart. This will be the overall width of the arbor.

Step 6

Mark and Chisel

On the 2x6 plank of pine or cedar, mark the width of the door span, adding one additional inch to each side to account for proper overhang. Cut a notch in the wood using a jigsaw, then use a wood chisel and hammer to remove the appropriate width necessary to accommodate the doors.

Step 7

Trace and Cut Template

Create a quarter circle template by tracing a round edge onto two pieces of scrap pine or cedar boards, then cut the pattern onto the 2x6 plank using the jigsaw.

Step 8

Attach the Arbor Tops

Position the outside pieces of wood so that they are flush with the edge of each door. Tap the wood with the hammer to secure a snug fit, then attach with 2-1/2” outdoor wood screws using the drill.

Once the outside pieces are secured into place, measure for the center, and install the third board.

Step 9

Cut and Attach Corner Braces

Create four corner braces from planks of 2x8 pine or cedar by cutting each plank at a 45-degree angle with the circular saw.

Pre-drill the braces with a 1/8” drill bit, then attach them using 2-1/2" wood screws.

Step 10

BPF_original_pergola-from-repurposed-doors_beauty-b_3x4

BPF_original_pergola-from-repurposed-doors_beauty-b_3x4

Photo by: Brian Patrick Flynn

Brian Patrick Flynn

Paint, Dry and Enjoy

Wipe all surfaces of doors and arbor top with a damp cloth or sponge. Prime and paint the doors, decorative ledge and arbor top with exterior latex paint using a paintbrush or roller.