Build a Redwood Screen Door

Materials and Tools

two 1/2-inch base frame redwood sides (2-7/8 by 80-inches)
three 1/2-inch base frame redwood top, bottom, and crosspiece (2-7/8 by 30-inches)
two 1/2-inch top frame redwood sides (2-3/8 by 75-1/4 inches)
two 1/2-inch top frame redwood top and bottom (2-3/8 by 35-3/4 inches)
1/2-inch top frame redwood for cross piece (2 by 30-inches)
1/2-inch base frame redwood for diagonal cross piece (2-7/8 by 42-inches; long point to long point)
1/2-inch redwood trim pieces
screen material
23-gage headless pinner
5/8-inch pins
1-inch pins
manual stapler
1/4-inch staples
miter saw
table saw
utility knife
safety goggles
pencil
carpenters glue

1. Lay out the pieces for the base frame, making sure the edges are square and flush. Glue the ends of the top and bottom pieces of the frame and attach to the sides. Use 1-inch pins to toenail the pieces together (figure A). (The term toenailing refers to attaching the ends of two boards together by nailing at an angle.)

2. Once the base frame is built, apply glue to the back of the 2-3/8 inch pieces that will make up the top frame. Apply over the base so they sit flush with the outside edges. The horizontal beams should overlap the seams of the base frame, making it a stronger structure door (figure B).

3. From the bottom of the door, measure up 30-1/8 inches and toenail the cross piece into the sides of the door. Make sure it is completely flush with the base frame.

4. Attach the 2-inch upper cross piece on top of the lower one.

5. Place the screen material over the lower portion of the door and staple to the 1/2-inch lip of the base frame with a manual stapler using 1/4-inch staples. Use plenty of staples, inserting as far as possible so they'll stay secure over the long run. Repeat for the upper portion of the door (figure C).

6. Once the screen is attached, remove the excess material with a utility knife.

7. Now insert the diagonal cross brace into the lower section of the frame. Measure diagonally from corner-to-corner, and cut a square piece of redwood to size. Hold the brace in place and mark where the corners will need to be mitered to fit. Cut and install by toe nailing with 1inch pins (figure D).

8. Miter and place trim around the door over the lip of the base frame. The trim will make the door more attractive by covering the staples holding in the screen. Attach trim using 5/8-inch pins (figure E).

9. Add hinges and a door handle, then install the door.