How to make a metal shed door

Written by arlene mason | 13/05/2017
How to make a metal shed door
Corrugated aluminium comes in many different styles. (coddy/iStock/Getty Images)

If the door to your shed is missing or if you just want a new door, making a replacement metal shed door is easy. Using 5 by 10 cm (2 by 4 inch) boards and a piece of corrugated aluminium you can replace your metal shed door in no time. This project will take only a couple of hours to put together.

Measure the length and width of the door opening. You will need to purchase a piece of corrugated aluminium that is this size. Also pick up 2 wooden ripple boards that are the width of the door. These will be found near the corrugated aluminium.

Buy two 5 by 10 cm (2 by 4 inch) boards the width of the door, four the length of the door and one the diagonal length of the door.

Check your measurements again, before you cut the wood. Then cut the wood to the appropriate sizes. Measure twice, cut once.

Arrange two of the long boards and the two ripple boards in a rectangle on the ground, with the ripple boards at the top and bottom.

Place the aluminium sheet on top of the boards.

Starting at the top, screw the aluminium to the ripple board, using 2.5 cm (1 inch) metal screws. Drive these at equal intervals. Do the same at the bottom.

Place a short 5 by 10 cm (2 by 4 inch) board on top of the aluminium and screw it down using 7.5 cm (3 inch) metal screws at equal intervals. Be sure this goes through the board, the aluminium and the ripple board. Also, be careful that you are not placing the long screws on top of the short ones. Do this at the top and bottom.

Place the remaining long boards on top of the aluminium, directly above the first ones. Screw them down using the 7.5 cm (3 inch) metal screws, at even intervals, through the aluminium and into the boards below. Do this on both sides.

Turn the door over.

Place the longest board diagonally, from one corner to the opposite, and screw it down at the corners, using the long screws. This is the inside of the door.

Turn the door over again.

Using the short screws, screw the diagonal piece down wherever it touches the aluminium.

Install the hinges on one side of the door and the hasp on the other side.

Lastly, install the door on the shed, installing the hinges and hasp on the appropriate side of the shed.


Remember: Measure twice, cut once!

Things you need

  • 1 sheet of corrugated aluminium
  • 2 ripple boards
  • 5 by 10 cm (2 by 4 inc) boards
  • 7.5 cm (3 inch) metal screws
  • 2.5 cm (1 inch) metal screws
  • Power screwdriver or drill
  • 2 hinges
  • 1 hasp

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