Steel doors have become widespread. The reason for their popularity is obvious. They are capable of providing more serious resistance to attackers than traditional wooden door. A similar structure can be placed at the entrance to a residential building or store, and can be used to equip the entrance to a warehouse, basement and other utility rooms. There are many models of similar products on the market. But if for some reason you are not satisfied with it, you can always make an iron door with your own hands.

First of all, you should take care of the tool. In order not to create unnecessary problems for yourself, it is better not to skimp on it. To complete the work you will definitely need:

• . Gas equipment poorly suited for the task at hand.
• Welder's clothing - protective apron, gloves and respirator.
• Angle grinder, popularly called an angle grinder. It is best suited for quick cutting and processing of metal.
• Mechanic's tools - pliers, pliers, hammers, screwdrivers, etc.
• A drill, preferably an impact drill, with a set of drill bits for metal and stone.
• Brushes, roller or spray for applying anti-corrosion protection and paint.
• Measuring tools - ruler, tape measure, angle, level and plumb line.

Step by step

The creation of the structure will occur in several stages, each of which must be completed before you move on to the next.

• Whether you like it or not, you will have to develop at least a rough draft. Otherwise, it will simply be impossible to guarantee the door’s functionality. To do this, first of all, you should take careful measurements of the opening into which the door will be installed. Using a level, you should make sure that there are no distortions in the opening; use a ruler or tape measure to measure its height and width, as well as the thickness of the walls. If distortions are detected, they must first be leveled, and then all measurements must be taken again.
• Then we select the material. Required metallic profile for the manufacture of the door frame and its frame, and steel sheet for cladding. A square profile pipe, for example, 40x60 mm, is suitable as a material for the frame. It has the necessary strength and fits well in size. The metal for the cladding must be at least two millimeters thick.
• After this, we select the steel grade. Let’s make a reservation right away - materials with maximum strength that can withstand the most advanced burglary means belong to the third group of steels and have poor weldability. Welding it will require complex technologies that only serious production has at its disposal. This means that you will have to choose between steels of the first and second groups, which have good and satisfactory weldability.
• It is worth taking care in advance to protect the door from corrosion. And, as surprising as it may sound to many, you will have to abandon the galvanized sheet. First of all, because at the welding site the galvanized layer will certainly be damaged and a so-called chemical electric couple will arise, due to which corrosion will rapidly progress. IN industrial production There are technologies for restoring zinc coating. In everyday life, you should limit yourself to buying a clean steel sheet, on which you will have to apply anti-corrosion and paintwork. Do not forget that zinc burned during the welding process is very harmful to health.
• In accordance with the measurements taken, we design the box and frame. You will have to start with the box, using the same pipe that will be used to make the frame of the canvas. Of course, the box can be secured with anchors directly to the wall. But for greater reliability, it is recommended to first make a U-shaped profile from a steel sheet and, covering the perimeter of the opening, fix this particular protection with anchor bolts. When this is done, it will be possible to weld the door frame elements to the resulting structure without any problems, as shown in drawing No. 1.
• The next step is to make the frame of the door leaf. There are projects in which profiles of different sections are used for this. Theoretically, this should reduce the cost of the design, but in practice it complicates its manufacture. It will be easier to weld the frame from the same profile. Approximately as shown in drawing No. 2. You will have to select the size of the cells yourself, since it is directly related to the size of the cell itself. doorway. Between door frame and the canvas must provide a gap of at least 3 mm. Otherwise, the door simply will not open normally. If you intend to weld the end of the door around the perimeter with a steel sheet, which is actually not necessary, you will have to make an additional indentation on each edge for the thickness of the metal. It’s worth taking care of the space in advance. door lock. How to do this is also shown in drawing No. 2. This is better than cutting already welded fabric.
• The front side of the canvas is best made from a single piece of sheet. The pre-made blank must protrude beyond the edge of the frame so as to overlap the gap in the doorway by at least 10 mm. The workpiece is laid on the floor, after which the frame is placed on it and welded. In order not to burn through the steel sheet and minimize damage, it is recommended to use a semi-automatic welding machine for work. Electrode welding is somewhat less suitable for these purposes. Of course, there are also virtuosos gas burner, but it all depends on skill.
• Next, you should apply anti-corrosion mastic to the inner surface of the resulting structure. There is no shortage of such compounds in auto chemical stores. You can choose the brand of your choice and apply it according to the instructions.
• It's time to think about thermal insulation. It is best to use mineral wool for these purposes. It performs its functions well and will not burn when it comes time to weld other elements of the fabric. Pieces mineral wool placed inside the cells of the frame. But you can go another way. To do this, you will have to complete all the welding work, and only then, through specially made holes, fill the door cavities with aerosol thermal insulation, such as liquid polyurethane foam.
• Now it's time to install the inner lining of the canvas. It is better to make such a part in one piece, drilling a sufficient number of holes in the places where the sheet will come into contact with the frame. Subsequently, through these holes it will be possible to weld the element into place.
• You can also choose the design of the hinges as desired. The main thing here is that they can withstand the weight of the canvas. Do not try to install a door with three or more hinges - it is impossible to arrange them coaxially so that they take the load at the same time and only two will actually work. It is best to weld them in place, having previously placed the canvas in the opening.
• After making sure that the door opens and closes normally, it should be painted. In some cases this may be sufficient. Well, if you have a desire, you can fix it on its sides decorative cladding, choosing the material to your liking. It can be wood, leather or plastic. The easiest way to fix such a cladding is with glue.

Iron door own production- this is not science fiction, but a doable task for those who know how to handle an angle grinder and a welding machine. And although the work is indeed not easy, it is worth considering that it is a metal structure that can protect an apartment or house at the maximum level. The performance is better thanks to the reliability of the material used and personal control. Let's look at the whole process step by step.

Required Tools

The production of metal doors begins with a selection of tools and auxiliary materials. You will need:

• Bulgarian;
• welding machine;
• cutting wheel for metal;
• grinding attachment;
• roulette;
• pencil or chalk;
• file.

To make iron doors you will need the following materials:

• sheet of metal with a thickness of at least 1.5 mm;
• steel corners or corrugated pipe 40x40 and 50x50 mm;
• insulation;
• finishing material;
• loops;
• lock.

Measurements and preparation of parts

The production of doors begins with the development of a drawing. The design must include such elements as a frame, fabric and stiffeners. First of all, use a tape measure to determine the width and height of the doorway.

This takes into account the dimensions of the box, the insulation layer and the external finish.

We transfer the parameters to paper. We draw a diagram of the future door and indicate the height and width of the door. Dimensions are taken into account along the perimeter of the frame. To these you need to add the thickness of the seal. Based on these numbers, we calculate the dimensions of the solid sheet and internal stiffeners.

Now you need to cut all the structural elements. To do this, markings are transferred to the metal according to the developed scheme.

The canvas is cut from of stainless steel. It is best to use a solid sheet of iron, since the presence of additional seams on the surface of the doors will not only distort their appearance, but also affect their strength.

Then we make the frame. The corners are cut to specified lengths. The edges need to be sawed off in such a way that it is convenient to weld them together. It is better to cut the stiffening ribs after the canvas is connected to the frame in order to match the dimensions to the nearest millimeter.

To do this job as quickly as possible, use a grinder with a metal cutting disc. The edges of the iron must be cleaned to avoid injury from sharp cuts.

Welding

The next step is to weld the structure. We connect the frame parts together. We make sure that the diagonal does not shift. It is recommended to tack first to ensure that the corners are in the correct position. If all sizes match, you can continue cooking. To do this, use a double-sided seam.

Then the door leaf - a prepared sheet of iron - is welded to the frame. First you need to clean the surfaces using a grinding attachment on an angle grinder.

Next you need to weld the stiffeners. At least one corner is used. It is placed in the middle of the canvas. If you want to strengthen it further, you can install one or two more, depending on the total weight of the structure. At the end of the work, all seams must be cleaned with a grinder using sanding attachments.

At the next stage, you need to make holes for the handle, locks, viewing eye and weld the hinges.

Insulation

Next, the homemade steel door needs to be insulated. This can also be done with your own hands using sheet materials. To begin with, it is recommended to attach a heat-reflecting substrate from the inside. Foam plastic, polyurethane, isolon or another type of insulation is laid on top. All cracks and joints are sealed with sealant. To seal the fit of the doors to the frame, you need to stick a rubber strip. A sheet of plywood or MDF panel is fixed on top of the insulation using liquid nails or screws.

Decorative finishing

The production of the iron door is being completed decorative finishing. The following materials are used:

• laminate;
• MDF overlays;
• veneer;
• soft upholstery;
• paint.

After sanding the seams, you can begin painting. First of all, the canvas and box are cleaned of dirt and degreased, for example, with White Spirit. Seal the peephole, if there is one. Apply a metal primer with anti-corrosion properties. Then they paint. For this purpose, you can buy nitro enamel, metal paint directly for rust, hammer, alkyd, acrylic enamel primer and others.

Decoration can be done using overlays. For example, to make the cladding yourself MDF doors panels, you will need glue. It must be applied to a clean, grease-free surface. Edge tape is applied around the perimeter.

If you figure it out, designing an iron front door yourself is not that difficult. The only condition is accuracy and adherence to technology.

High quality steel door, even with budget hammer painting, now costs good money. Of course, cheap Chinese products that can be opened with a can opener are not taken into account. Therefore, a homeowner with below-average income has no choice but to make a metal door and install it with his own hands, or order it from some garage technician. But if you are familiar with the welding machine firsthand, then there is no need to pay for someone else’s work - read our article about the manufacturing technology and get to work yourself.

Preparing for work

At this stage, you need to take measurements of the entrance opening and prepare all the necessary materials. The list of tools is standard - measuring devices, welding and a grinder with a drill.

Advice. To secure the welded units, be sure to prepare 2-3 clamps; without them, working is much more difficult.

Measuring the opening at the entrance to the apartment or a private house produced in several places, especially in width. It is necessary to identify the narrowest point in order to focus on this size during manufacturing. Apply the measurement results to the diagram according to which you will prepare the metal.

It is assumed that you do not have personal experience in assembling iron doors, so to begin with, we suggest making the simplest design. Even if it doesn’t turn out too beautiful, you will subsequently cover the sash with insulation and decorative overlays that will hide all the minor flaws. From construction materials you will need:

• 1 standard sheet of steel, preferably cold-rolled, 1.5-2 mm thick per sheet;
• for the frame and door frame, take a profile pipe with a cross section of 40 x 20 mm with a wall thickness of 1.5-2 mm;
• canopies 2 pcs. (you need to order a turner) and metal plates 4-5 mm thick for their installation;
• a simple and reliable door lock, or a homemade one.

Design drawing from corners

Advice. There is no point in taking metal that is too thick (for example, 3 mm), since it will still not be possible to weld a real armored door, and the product will be too heavy. A thickness of sheet and professional pipe of 1.5 mm is quite sufficient. Instead of the latter, you can use an equal angle corner 45 x 3 mm.

If your welding skills have not yet been honed, then it is better to take a steel sheet 2 mm thick, it is more difficult to burn through due to lack of experience. Also think about the future exterior decoration to select materials in advance. Read more about preparatory stage Making a metal door with wooden overlays is described in the video:

Door Making Guide

The first operation is the preparation of parts. It is performed according to this scheme:

1. Cut 4 profiles for the vertical posts of the door frame (or 2 corners), guided by the drawing.
2. Prepare 4 box crossbars from corrugated pipe or corners.
3. For the canvas frame, cut 4 horizontal lintels and 2 racks.
4. Using a grinder, adjust the dimensions of the steel sheet to the dimensions of the door frame.

Drawing of a door made of corrugated pipe in the entrance opening

Note. Between door block and the wall, provide 1 cm gaps around the entire perimeter, as shown in the drawing. On the rebates, a gap of at least 4 mm must be maintained for the sealing tape.

After cutting the elements of the product, clean the sharp ends and remove burrs, then proceed to assembly. To make it easier for you to process before painting, at this stage it is recommended to remove all rust from the surface of the workpieces using coarse sandpaper and a wire brush.

Making a door leaf

Traditionally, welding an iron door with your own hands begins with making a frame, into which the finished leaf is then inserted. But personal experience many craftsmen say that it is worth starting with the canvas - this way it is easier to maintain an angle of 90° and prevent a “helicopter”, in which the product is skewed relative to the frontal plane.

First of all, lay the sheet of metal on a table or stand and level it flat using a building level and shims in in the right places. Then proceed in this order:

1. Lay out the frame blanks on the sheet, leaving 1 cm from its edges and maintaining 90° angles. Tack the upper and lower cross members by welding at several points, securing them with clamps.
2. Repeat the same operation with vertical posts, performing tacks on the inside of the profile. How it looks visually is shown in the photo above.
3. Finally weld the frame elements with the sheet and with each other. Install 2 intermediate jumpers and secure them in the same way.
4. Finally, clean all welds with a grinder.

Attention! When connected profile pipe Do not make continuous seams with the fabric, otherwise the metal will move and at the end you will get that very “helicopter”. Fuse points on the inside every 10 cm.

We weld the box

In our case, the outer frame is mounted from two profiles installed at an angle of 90° relative to each other (see above in the drawing). Therefore, first form the outer frame by laying profiles along the entire perimeter of the canvas and fastening them with tacks.

The next corrugated pipe is laid flat on the previous 2 with an overlap and forms the internal frame of the box. Study the photo carefully to understand this combination.

When all the frame profiles are in place, grab them and then spot weld them together. Be careful not to mistakenly weld the frame to the door leaf. Visually, the finished box lying on the sash looks like this:

Before the next operation, you need to separate the canvas and the box, and turn the latter over and put it on the work table. Now you can thoroughly weld the joints from the outside and sand them with a grinder. Do not place sutures on the inside where the sash will rest.

There is no need to seal the joint from the inside, only from the outside

Important point. Before removing the frame from the door leaf, place marks on both elements to remember their position and during assembly not to confuse the top and bottom.

We install awnings

To continue working, you need to put the finished sash on the table again, only now on top of the box. At this stage, it is important to clearly check all the gaps: the gaps from the edge of the canvas to the outer cut of the tray should be uniform around the entire perimeter and be 1 cm, the size of the rebate gap for laying the sealant should be 4-6 mm. To ensure this, slip gaskets of the required thickness under the steel sheet.

Now about how to make canopies correctly:

1. Determine the position of the canopies by measuring the same distance from above and below - 25 cm. Make marks and cut grooves in the canvas with a grinder in order to weld the hinges directly to the frame profile, and not to the sheet.
2. Weld a thick plate to the top of the canopy, fitting the parts in place to the end of the beam.
3. Attach the loop with the plate to the box so that there is a gap of 3-5 mm between it and the plane of the sheet. Tack the part by welding.
4. Place the second amplifier on the door leaf and weld it with the canopy and leaf. Repeat all operations on the other loop.

When the iron door is held on by tacks, check its opening and fit, then finally weld the awnings and clean the seams.

Installing a lock

When a freshly made front door has not yet been placed in the opening, installing locks with your own hands is not a problem. To begin, attach the lock to the end of the canvas and outline its outline.

To cut a groove for the lock, use a grinder and a drill. When you remove the cut piece of metal, align and clean the edges of the opening.

1. Insert the lock into the groove and drill holes for fastening. Cut an M5 or M6 thread into them and secure the product.
2. Opposite the hole in the body for the handle and keyhole, place marks on the door leaf. Cut the same openings in it and place a handle with an overlay on the outside.
3. Determine the location in the door frame where the lock bolts should fit into the holes when closing. Make these grooves, clean them up and check how the lock works. If necessary, adjust or widen the opening.

When finished, make 4 mounting holes in the box where the anchor bolts will fit during installation. More information and important points You can learn about making an iron door by watching the video:

Product cladding

Whatever method of finishing the door you choose, first it must be protected from corrosion - primed and painted. To do this, you need to remove slag from the welds, clean them and degrease the entire surface, and then apply 2 layers of primer. After drying, paint the product 2 times, starting from the back.

You can decorate your entrance doors in the following ways:

• insulate the inside with polystyrene boards, placing them on glue, and cover them with plastic panels;
• screw the outer and inner wood lining, in particular lining, with self-tapping screws;
• cover the canvas with leatherette, laying a layer of insulation under it;
• buy and install a ready-made kit for MDF doors.

You can make platbands from iron and paint them the same color

The finished product is installed in the entrance opening on anchor bolts, and the cracks are traditionally sealed with polyurethane foam. Here it is important to maintain horizontal and vertical lines so that the door closes well and the loot is not “piled up” inside the apartment. To hide the foam, the outside and inside of the box is lined with platbands made of wood, metal or plastic. The correct painting of the door leaf is described in detail in the latest video:

Conclusion

Homemade iron entrance doors are not inferior in service life to factory ones, if the technology was followed during the manufacturing process and the structure was welded without distortions. Otherwise, problems will arise, first of all, with the lock, which will begin to close poorly and jam. To prevent this from happening, spend more time adjusting all elements during the assembly process, when errors are easier to correct.

In the presence of welding machine and even if you have little skill in working with it, it would be simply unreasonable to purchase a Chinese product that is not very durable. Entrance steel door made with your own hands will become more reliable protection from burglary and bad weather. Let us describe in detail the process of its manufacture.

Required materials and tools

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Free instrument 50% success

Before you start making a metal structure, you should prepare the necessary materials and tools for the work.

We will need:

• yardstick
• carpenter's square for taking measurements;
• metal corner for the door frame and door frame; it can be replaced with a square pipe 40x40 mm; for the manufacture of the internal frame of the box and stiffeners, slightly smaller pipes of 40x20 mm are used
• metal sheets: you should not take material that is too thin; its thickness should be at least 1.5-2 mm
• welding machine
• grinder or wire brush for cleaning welds
• drill with drill bits
• metal anchors or pieces of reinforcement for attaching the structure to the wall
• screws, bolts
• wrench suitable size for tightening bolts
• screwdriver
• door hinges capable of supporting the weight of a door weighing over 100 kg
• rim lock
• plywood, MDF, lining or laminate for finishing

Taking measurements

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Welding a metal structure

Even when using standard drawings to assemble an iron door, you will need to take measurements. Ideally even, symmetrical doorways simply do not exist. Therefore, it is necessary to be extremely careful when taking measurements.

One measurement will not be enough - you need to take measurements three times and then select the smallest number obtained. The door leaf should be measured at the top, bottom, and middle.

The height of the opening is determined in exactly the same way. If the old doors have not yet been removed, it is easier to measure them.

In most cases, the width of the canvas is a multiple of 10 cm - its width can be 70, 80 or 90 cm. Please note that the size of the future opening should be 1.5-2 cm smaller sizes the opening itself. The remaining cracks are subsequently filled with polyurethane foam. After all, it will be difficult to insert and perfectly align a door cut exactly to the size of the doorway.

Immediately determine which direction they will open. According to SNiP, entrance doors must necessarily open outward, so that in the event of an evacuation or transfer of a sick person, it can be opened without hindrance. In this case, it will also be possible to save useful space in the hallway.

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How to correctly measure the width of an opening

The opening side is selected taking into account comfort and convenience. Traditionally, doors are made right-handed so that upon entry they can be opened using right hand. But this option can be changed taking into account specific circumstances.

After all, the door should open so as to occupy a minimum of free space without creating interference. IN apartment buildings The location of adjacent doors is also taken into account.

Door frame

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So, we will describe in detail how to make an iron door yourself:

1 After cutting a metal corner or pipe to the specified dimensions, you need to fold the resulting parts into a rectangle on a flat surface or welding table, once again double-checking its dimensions.

2 There is no need to cut 45° corners. The metal strips are simply joined end to end.

Metal strips are joined end to end

3 We weld the inner frame from the corner with the smaller shelves. The distance between it and the frame is 3-5 mm.

4 Stiffening ribs are welded from the same corner - sections that are inserted inside the frame.

5 Don’t forget to thoroughly clean all seams with a sander, special abrasive fiber, brush, or pickle them with a seam treatment agent. Otherwise, the smallest remnants of metal, and behind it the metal corner itself, will immediately begin to rust. It is more convenient to grind off large deposits with a grinder or a file.

6 A fairly common mistake made by novice welders is to immediately connect the frame parts cleanly, “tightly”. There is no need to do this under any circumstances - most likely, the frame will have to be trimmed. Therefore, first you just need to “grab” the metal corners, and then align the assembled door frame with a building level not only horizontally and vertically, but along the corners and both diagonals.

7 Check that all parts fit exactly at 90°. Final welding can only begin after alignment.

Frame with internal frame

8 The next step is drilling holes for anchors and attaching hinges. At the same stage, holes are prepared for the lock bolts.

9 To attach the sealing rubber and protect the frame from deflections, small metal plates are welded to it.

10 To insert the frame into the doorway, you can weld steel eyes to it or provide through mounting holes.

Finished door frame

Door leaf

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1. The height and width of its frame must match the size of the door frame minus 5 mm on each side for the door to move freely.
2. After cutting the sheets (this can be done with a grinder), we clean the edges from burrs with a file or grinder with emery.
3. Metal sheets are attached to the frame so that they protrude 10 mm at the top, bottom and on the lock side. The allowance on the hinge side is made slightly smaller - 3-5 mm.
4. After “grabbing” the sheets, we check the correctness of fastening, and then weld the seams completely. If the sheets do not move, we proceed to final welding. First, we “sew” them to the main frame, and then attach them to the intermediate stiffeners. There is no point in making continuous seams - it is enough to weld the sheets in small sections.
5. The cutout for inserting the lock must be provided before the sheathing.
6. At the same stage, you can attach a wood frame to the door leaf to secure the trim. To do this, holes are drilled in the metal in the right places.

Single sheet metal door design

Connecting the door leaf to the frame

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1. Just as with the previous assembly, the seams should first be “tightened” by welding. The final connection is made only after checking the correct installation.
2. We drill holes for inserting a key and, if necessary, a peephole.
3. To attach the hinges, you need to step back 20 cm from the bottom and top of the door.
4. Raise the door (it’s easier to do this together). We fasten the canopies in such a way that the lower elements (the pins are attached to them) are attached to the frame, and the upper ones, called counters, are attached to the door leaf.
5. All loops must be located strictly along the same axis. This is not easy to do - you will have to take measurements many times. Otherwise, if an error occurs, the door will warp.
6. It is better to hang a massive door not on 2, but 3 hinges.
7. Lubricate them immediately so that the door opens easily and does not creak.

Entrance metal structure

Even if the door will be upholstered or finished in the future decorative panels, it should be treated with an anti-corrosion compound or painted. For painting metal, it is better to use the so-called “hammer” enamel, made on an alkyd-styrene base.

Insulation

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Insulate an iron door welded from metal You can use expanded polystyrene, polystyrene foam or mineral wool. When using polystyrene foam, sheets 4 cm thick are sufficient. Too much density of the material is not needed - after all, the load on it will be small. You will need to purchase 4 square sheets of 1 m wide.

At the time of buying polyurethane foam choose a composition with minimal expansion, otherwise the foam will simply squeeze out. We apply it around the perimeter of the frame, stepping back slightly from the edges. Next, polystyrene foam is laid. All seams between sheets, gaps between foam plastic and metal corner should also be sealed with foam. It can be replaced with Moment glue or any other suitable adhesive composition.

Installation of insulation

Mineral wool or stone wool has a significant disadvantage– these materials are capable of absorbing moisture. A metal door with this type of insulation will quickly rust. For apartment buildings this is not critical - there is not so much moisture in the entrances. But it is highly not recommended to insulate a street door with mineral wool.

If in the future the door is finished with self-adhesive film, There is no need to cover the insulation with chipboard. Any irregularities will be immediately visible. Replace Furniture chipboard moisture resistant plywood. It is attached to the metal using self-tapping screws through pre-drilled holes.

Metal door covered with film, trimmed with molding

You can decorate a door covered with film with moldings - decorative strips made of metal or polymer materials, painted to resemble wood, stone, silver or gold.

Inserting a metal door into an opening

Install massive metal structure alone is unrealistic. You will need an assistant.

Removing the old door

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1. Before installing iron doors, the old door leaf should be removed from its hinges. To do this, place a crowbar under its bottom, lift the structure and remove it from its hinges. Some types of hinges have to be unscrewed. This must be done starting from the bottom.
2. After dismantling the slopes of an old metal door, you need to find its attachment points. To do this, plaster is knocked down in the area of ​​the proposed anchors or reinforcement. All metal parts are cut off with a grinder, and then the old box is pulled out.
3. A regular wooden box is easier to remove. It is enough to cut the side posts in the center, and then, using a crowbar, pry them out of the opening.
4. All loose pieces of brick and putty should be knocked down. The resulting voids are filled with new bricks and then covered cement mortar. Small potholes will be filled with foam in the future, so you can leave them alone for now.
5. Significant protrusions are knocked down with a hammer or cut off with a grinder.
6. Pay attention to the condition of the threshold. In old houses in these places they install wooden beam. If it is damaged, the beam needs to be replaced. You can check its safety with an awl. Insert it into the wood and try to loosen it. If this can be done easily, the timber has become unusable.

Removing the door frame

Door insert

1 It is more convenient to install it with the door leaf removed from its hinges.

2 The frame is installed on pads 2 cm high. With their help, the structure will be leveled. If when welding front door no mistakes were made, and all measurements were carried out correctly, it should enter the opening freely.

3 We check the horizontal and vertical position of the structure with a bubble or laser level. When checking vertically, you can use a plumb line - a weight suspended from the side.

4 After leveling, we wedge the door frame using wooden or special plastic wedges. They are located closer to the fastening points. There should be three of them on the sides, two on the top.

5 We check again with the level to see if we accidentally moved the frame to the side.

6 There are two ways to fasten metal doors. In the first case, the lugs should be pre-welded to the frame. If the walls are not thick enough, through holes are made in the box into which anchors or small pieces of reinforcement will be inserted.

Door fastening methods

7 To install anchors or reinforcement in the wall, you will need to prepare holes with a depth of 30 cm. The size of the drill must match the diameter of the fastener. You can mark the drilling depth on it using masking tape.

Installation of anchors

8 After inserting anchors or reinforcement, they are additionally driven in with a hammer. If you need to move the fastener slightly, insert a screwdriver between it and the wall, tapping it with a hammer.

9 Fastening begins from the hinge side. Then two fasteners are inserted from above, below and one from the side of the lock. The anchors should not be over-tightened - the door frame may need to be adjusted.

10 We check with a level to see if we have displaced it when driving in the fasteners.

11 We hang the door leaf. Let's check its progress. If there are distortions, cracks, or jammed locks, you will have to remove it and re-align the position of the box horizontally and vertically.

12 If the door leaf is installed correctly, it must be removed again and the anchors finally tightened. First, tighten the bolts from the hinge side, then from the lock side. The last ones are the bottom and the top.

13 After the final hanging of the web, its progress is checked again.

14 To create a reliable sound and heat insulating barrier, all gaps between the door frame and the wall are filled with foam. Its expansion coefficient should be minimal - it is easier to work with such a solution.

15 Excess foam should be removed immediately with a damp cloth. If you delay a little, after 5 minutes it will be problematic to erase it - the surface of the door will have to be scraped.

It's no secret that today such an element as a metal entrance door is not a luxury, but a mandatory attribute of any residential premises, including a private house or apartment, as well as various administrative and office buildings.

Thanks to the modern development of technology and the emergence of innovative materials, you can personally design any, even the most complex, item needed in everyday life. A metal door is no exception: if you have some construction skills, you can easily equip this element yourself, thereby saving yourself from the need to overpay for installation already finished model. In addition, it is much more pleasant to arrange your home at your own discretion, without using templates. Therefore, we should take a closer look at how competently it should be. But first, you should pay attention to the list of advantages that this functional part of the house has.

The main advantages of a metal door

Thanks to the ability to use modern materials for insulation, this element can provide excellent protection from noise and from cold entering the room, which is especially important in cold climates. Insulated metal doors are a guarantee that you will not freeze in your home.

Another reason to create such an irreplaceable attribute of everyday life with your own hands is its excellent appearance, which makes it possible to transform a seemingly standard part of the home into a unique and unique element with high aesthetic values.

Perhaps the main advantage of a metal door is its high resistance to burglary, coupled with the possibility of installing additional security measures (various limiters, etc.). This will completely protect the home from the entry of unwanted persons and will save the nerves of its owners.

It is these advantages that are the key factors influencing such a decision,

Doorway measurements

As in any other matter, you must first perform all the necessary calculations. When making an element such as a metal door, you first need to take measurements of the opening with your own hands. The door leaf and frame will be designed in accordance with them. It is important to remember that it is extremely important to subtract 2 cm from all the parameters obtained during the measurement process. This small gap will subsequently make it possible to adjust and align the door in the opening. Measurements must be taken for the entire length and width of the desired hole, that is, starting from the base in the form of brick or concrete, and not from plaster. This needs to be done exactly this way, because the finishing material can be applied in a thick layer, and if the calculation is incorrect, the parameters of the finished door may not coincide with the actual parameters of the installation site.

Tools and materials for work

The equipment required to make a metal door yourself includes the following set of tools:

• welding table;
• an angle grinder equipped with a metal wheel;
• welding machine;
• screwdriver;
• drill with several drills;
• roulette and others measuring instruments;
• and screwdrivers.

As for the materials that will make up the door, their set is as follows:

• metal corners for the box or a steel pipe with a square profile;
• sheathing material in the form of plywood, veneer, boards, etc.;
• metal sheet with a thickness of at least 1.5 mm;
• door hinges;
• accessories (handle, locks);
• fastening elements (screws, bolts, etc.).

Door frame design

It’s absolutely possible to do it yourself, and all the work should start with making a box for it. This element consists of securely welded corners, which form its basis. It should be remembered that after installing vertically and horizontally located parts, it is necessary to leave gaps that will be required in the future.

It is necessary to place a corner or square-shaped profile on the welding table and cut it according to the required parameters. The finished parts need to be laid out in a rectangle and all the parameters must be checked again.

It is very important that all angles are exactly 90°, so you need to carefully study the diagonals, measuring the distance from one end to the other. Once all calculations are completed, you can begin welding the door frame. At this stage, it is allowed to make slits in it. To do this, use a grinder.

When installing an element such as a metal door with your own hands, the drawings must be made as correctly as possible so that the design fully complies with the pre-drawn project. Otherwise, the result of the work may not be at all what was originally expected.

Door leaf installation

First of all, you should clearly determine the size of the potential canvas. To do this, you need to measure the parameters of the inside of the box and leave a gap of about 0.5 cm on each side. It is based on these indicators that a metal door should be made with your own hands, the drawings for which, in turn, help to complete all the work as quickly and efficiently as possible.

Next, you need to weld a frame consisting of corners intended for the canvas. The process of its manufacture resembles in its actions the creation of a box. From the inside, parts of the corner must be welded to the frame at the same distance from each other. These elements will serve as stiffeners.

The next procedure that should be performed when making a house element such as a metal door with your own hands is to cut out a steel sheet. It must correspond to the parameters of the frame, and it is extremely important to maintain an allowance of 1 cm on each side, as well as 0.5 cm on the side of the hinges. This sheet must be welded evenly to the door base, while not forgetting to remove any burrs that appear and correct uneven seams using a grinder. At this point, the manufacture of the door leaf can be considered complete.

Fixing a metal door on hinges

These elements must be welded according to a special scheme. As a rule, one of the hinge parts, which has a special pin, is first attached to the box. Its second part is fixed directly on the canvas. It is very important to pay attention to the drawing of the metal door, according to which you should correctly calculate all the dimensions and measure the required distance for installing the hinges.

It is necessary that both of these functional parts match perfectly. This will not only avoid distortion of the entire structure, but will also improve its tightness and extend its service life.

When installing insulated metal doors, do not forget that for laying insulation it is also necessary to leave some free space inside the door leaf. This procedure will be more complicated, but such a measure will definitely protect the entire structure from the penetration of cold.

After installing the hinges, you need to clean the seams if necessary, and then paint the finished structure.

Equipping a metal door with fittings

When thinking about how to make a metal door of the highest quality, you should not forget that to create a reliable model Special attention it's worth paying attention to this important matter, such as installation and fixation of the lock mechanism.

For this work, you will need to purchase two different types of samples, which during installation should be positioned as conveniently as possible. It is very important that each of the elements of the lock fits the other, and that the entire system interacts smoothly and easily. A drawing of a metal door, of course, cannot reflect this, but it will be much better if the mechanism does not create unnecessary sounds (creaking, grinding, etc.) during opening.

After this, it is recommended to cut a special hole in the door leaf, intended for the installation of a good and modern door peephole, which has a wide viewing angle and can be closed if necessary. At this point, work with fittings can be considered completed.

Installing a metal door in an opening

To insert a ready-made door structure into the opening, the strength of at least two people will be required, since it will be problematic to do this work alone. In addition, you need to pay special attention to the following points:

• The box should be positioned geometrically evenly. All measurements can be taken using a building level.
• The structure must be fixed securely and tightly.
• All gaps formed between the wall and the door must be sealed using polyurethane foam.

The installation of the metal door is completed with another check of the reliability of the lock mechanism. In addition, you should make sure that the system opens in the desired direction easily and without any interference and closes just as easily.

A good addition to the aesthetic appearance will be the device as well as the design of its slopes. Such procedures will not only make the structure more beautiful, but will also increase its specifications, improving thermal and sound insulation.

Working with such a modern and necessary attribute of the home as a metal door, you can not only make the model itself with your own hands, but also decorate it beautifully.

Here, as always, the design is based solely on the preferences and tastes of the owners, but we should not forget about such an important factor as operating conditions, since it is not always possible to decorate different doors in the same way due to some external factors: climate, type of construction, etc.

As an option, you can use veneer or MDF; polymer painting is also suitable. This type of finishing, such as covering the door with a special film that protects against external mechanical damage, is also gaining increasing popularity.

One way or another, a metal door can be designed in different ways, but the main thing is that this element clearly performs its functions and is able to serve for a long time and reliably.