Don't Let a Cheap, Ill-Fitting Door Ruin Your Historic Home—Here's Why We DIY Ours

If you live in an old house, you quickly learn that nothing is standard. Doorways are rarely square, dimensions are unpredictable, and replacing anything often means making hard compromises between period-appropriate style, quality, and budget. That’s exactly how we ended up building our own doors—one for every year we’ve lived in our 200-year-old Queen Anne Victorian (so far!).

Why Build a Custom Door?

It all started with a simple idea: buy a new door. Sean was fully prepared to purchase one, but I didn’t love any of the options we found. They weren’t quite right in terms of style, wood type, or quality. That’s when Sean made the fateful suggestion: “What if I just build one?”

That offhand remark turned into something bigger than either of us expected. There’s a sentimentality to building a door. It’s one of the most frequently used elements of a home—an everyday interaction that quietly shapes the way you move through your space. Doors welcome you in, provide security and privacy, and, when crafted by hand, they leave a personal mark of ownership on a home.

Now, with four doors under our belt, we’ve realized each one tells a story. We look at them and see the hours of labor, the problem-solving, and the satisfaction of knowing that something so integral to our home is something we built ourselves.

The Doors We’ve Made

1. The Screened-In Porch Door

The first door Sean made was for our screened-in porch. We had found a design we liked, but it was expensive and had a long lead time. Plus, we realized that if we built the door ourselves, we could make it from the same clear cedar as the screen frames, ensuring a perfect match.

The hidden cost of DIY, of course, is time—and the occasional investment in new tools. But in this case, the trade-off was well worth it. Sean finished the door in August 2022, just in time for my birthday. Sitting on the screened-in porch, looking at that door, I feel an extra sense of pride and appreciation for all the work that went into it.

2. The Garden Door

Our second door followed a similar style to the porch door. We wanted something that blended seamlessly with the backyard aesthetic while being functional and sturdy. Like the porch door, it was built with clear cedar, a durable and weather-resistant wood that ages beautifully over time.

3. The Cellar Hatch Door

The third door was a departure from our previous builds. I had fallen in love with a cellar hatch door I saw in Sag Harbor and was determined to recreate the look. This one required a different construction technique, as it needed to be strong enough to withstand the elements while maintaining an old-world charm.

Interestingly, this door has become a bit of an unexpected design inspiration. Recently, someone who came to pick up a vanity we sold on Facebook Marketplace ended up taking a picture of the cellar hatch door because they wanted to build their own version!

4. The Cellar Door

Our most recent project was the cellar door. Built using tongue-and-groove mahogany, it was a labor of love that tested our woodworking skills in new ways. It also reinforced something we’d come to appreciate: the balance between form and function. A beautiful door isn’t just about looks—it also needs to open and close seamlessly, withstand temperature changes, and hold up over time.

Considerations When Building Your Own Door

1. Design

Gather inspiration from doors you love. Instagram, Pinterest, and historic home walks are great places to start. We’ve been focusing our designs on modern takes made with high-quality materials rather than period reproductions. Once you’ve found a look that speaks to you, balance that inspiration with simple construction techniques that you can realistically tackle with your skill set and tools.

2. Materials

Choosing the right material is critical. Here are some of the options we’ve used and why:

• Clear Cedar: Great for exterior doors due to its resistance to rot and beautiful grain.

• Tongue & Groove Mahogany: A rich, durable hardwood that gives a classic, high-end look.

• Plywood with Beadboard Overlay: A budget-friendly option that can still offer historic charm.

Consider factors when selecting materials like cost, weight, insulation, and how well the material will stand up to the elements.

3. Hardware

Hardware can make or break a door—both functionally and aesthetically. We initially tried reusing vintage latches on our garden and cellar doors, hoping to mix old and new for a timeless look. But we quickly learned that vintage hardware, while charming, often lacks the reliability and smooth operation of modern pieces. Now, we prioritize new hardware with a classic style, ensuring durability and functionality without the frustration of ill-fitting or finicky old parts.

4. Time Commitment

Building a door takes time—more than you might expect. On average, each of our four doors has taken about six weekends to complete. Between designing, sourcing materials, cutting, assembling, sanding, finishing, and hanging, it’s a significant project. But for us, that investment of time has been part of the joy of it.

5. Cost

A high-quality, period-appropriate custom door for a 200-year-old home can easily cost $3,000–$8,000 (or more) depending on the materials and craftsmanship—but by DIYing, we’ve been able to build each of ours for a fraction of that cost, often under $500 in materials.

Creating Home, One Door at a Time

Would it be easier to buy a door? Absolutely. But there’s something incredibly rewarding about walking through a doorway that you built with your own hands. Each door we’ve made has deepened our connection to this old house, reinforcing the idea that home isn’t just something you inhabit—it’s something you create.

If you’re considering building your own custom door, start small, do your research, and embrace the learning process. Who knows? You might just find yourself making one for every year you live in your home, too.

Thinking about building your own custom door? Drop your questions in the comments—we’d love to help! And if you want more behind-the-scenes looks at our DIY projects, follow along on Instagram @robinshollow. Already built (or planning to build) your own custom door? Tag us—we’d love to see your project!