How to Make a Dining Table from a Door

Step 1: Prepare the Door

1. Remove the old hardware by scraping away built-up layers of paint so the screwdriver has a firm grip on the screw heads. If screws remain stuck, loosen them with a sharp hammer blow to the handle of the screwdriver.
2. Remove the old glass by placing cardboard under and over the panels and smashing it out with a hammer. Use a chisel to scrape away putty and remove glazing pins.
3. Scrape off paint and trim use a hot airgun or hair dryer to heat the paint while removing it with a metal scraper, disposing carefully as it may contain lead. Mark 4-in. around the panels to square up the edges of the table with a circular saw.

Sue Ferris[+]

Sue Ferris[+]

Sue Ferris[+]

Step 2: Secure the Backing

Notch corners in the underpanel to allow for the legs. Put the backing in the panels, apply adhesive and secure the underpanel to the door with 1-in. screws. From the top, secure 1-in. screws through the backing to pull up the underpanel.

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Step 3: Position the Infills

Generously apply construction adhesive on the backing then secure three infill pieces in each panel. Core out and square up the lock and handle holes with a sharp chisel and cut matching infill pieces to fit, securing with adhesive.

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Step 4: Prepare the Rails

At the base of the end and side rails mark 3 1/2-in. from the ends and 3 1/2-in. from the top, joining with a curved line, using a circular saw and jigsaw to cut and a belt sander to smooth the outer surfaces of the rails.

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Step 5: Make the Dowel Joints

At the top of the legs and end of the rails, use a doweling jig to drill three 3/8-in. holes 1 3/8-in. apart. Do a test fit and adjust if necessary, apply wood glue in the holes and on the end grain of the rails, assembling with dowels.

Sue Ferris[+]

Sue Ferris[+]

Step 6: Assemble the Frame

Tap the legs and rails together with a mallet then position wood corner blocks at the outside corners to hold the frame and set up a long ratchet cargo strap to pull the frame tightly and leave to dry. Check legs are plumb and square.

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Step 7: Add the Corner Bracing

Position the corner braces 3/8-in. from the top of the legs to allow for the underpanel, securing with #8 x 3-in. screws into the legs and #8 x 2-in. screws into the rails.

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Step 8: Attach the Tabletop

To secure the tabletop to the frame, position one cleat on each end and three on each side by drilling two pilot holes into the rails and two clearance holes into the tabletop, securing with screws.

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Sue Ferris[+]

Step 9: Attach the Trim

Miter the trim, drill pilot holes then secure it to the tabletop with 1 5/8-in. screws, filling the screw heads with wood filler. Hand plane the infill pieces level then smooth with a belt sander using coarse sandpaper then a random orbital sander.

Sue Ferris[+]