DIY Iron door dupe

Several months ago I decided I was over the barn door look and also the functionality of it was not great when I was on phone calls with clients.

I knew that I wanted an iron door, but they are PRICEY!!!

I thought well maybe I could just order a door with full glass panel and make it work, but when they built my house, they did a cased opening and it was not a regular door size.

So back to the drawing board, I originally made the first frame out of 2×3’s, but realized that was no going to work. After waiting a couple weeks staring at this 2×3 frame that was put together, Frills and Drills off Instagram put on her stories that she was going to attempt to do the exact same thing I was doing. She started out with 1×3’s, so I went to Lowe’s and got me 1×3 boards and some 1×2’s.

Supplies I used

  • 6-1x3x8 Pine Boards
  • 3- 1x2x8 Pine Boards
  • Kreg Jig Screws
  • 24×36 Plexiglass panels ( had to cut down)
  • Plexiglass jigsaw blade
  • wood glue
  • Iron Ore Black Paint
  • Power Grab Clear
  • Kwikset door knob

After I made 2 of the same exact same frames, I cut my 1×2’s and did the sections for each glass panels on both frames. I then used a scrap piece of 1×3 to make the door knob area and attached it using wood glue and kreg screws.

Then I used a router and did a cutout for the glass panels to be able to go flush between the frames. I had to use wood chisel set to clean up what the router couldn’t do in the corners.

Next I got to painting it with Sherwin Williams Iron Ore paint and had to make sure to paint on both sides because you could see some of the wood through the glass.

After I had everything painted, I measured and using the plexiglass jig saw blade, I was able to cut it to the correct size. This part was nerve wrecking, but I love when projects test me and I learn new things and how to use new tools.

Once they were all cut I used the powergrab clear to adhere the panels to the wood and then used wood glue around the wood. I used clamps to hold together for over a day and then was ready to hang!!

I ended up having to router out for the hinges on the new door as well as the door frame and also for the door knob.

After hanging the door and touching up the paint, it was ready to use!!

I am in love with it and for under $200.00 that’s a fraction of what an Iron door would be!!

This was a fun weekend project and Thanks to Lowe’s I was able to get everything I needed.

Let me know if you have any questions!!

2 Comments

  1. googletest on January 23, 2024 at 3:36 am

    Greetings! I’ve been reading your site for a while now and finally
    got the courage to go ahead and give you a shout out
    from Houston Tx! Just wanted to mention keep up the great work!

    • ashleykmills on January 23, 2024 at 4:14 pm

      Thank you so much!

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