Measured assembly, in 3D.
Your 2×4 frame, 15/32-inch outside plywood and 1/5-inch inside plywood, with insulated panel fields and a clean center overlap.
09 October 2026
Equipment: imperial · cuts: cm
Right opens first. Left closes first. Animation uses an illustrative hinge axis.
Dimensions to carry to the workshop
Cuts and layout marks use centimeters. Purchased stock, hardware and equipment use imperial sizes. The 3D part inspector follows the unit selector and opens in inches. Verify the opening, timber condition and actual stock before cutting.
Opening and panel assembly
| Opening for cut layout | 257 cm wide × 216 cm high, assumed |
|---|---|
| Horizontal fit marks, cm | 0.635 + 127.565 + 0.6 + 127.565 + 0.635 = 257 |
| Vertical fit marks, cm | 1.5 bottom + 213.865 leaf + 0.635 top = 216 |
| Outside / core / inside | 15/32 + 1-1/2 + 1/5 = 2.16875 in |
| Main skin + joint + strip, cm | 121.92 + 0.32 + 5.325 = 127.565 |
| Layout on meeting stile, cm | 3.245 main-sheet bearing + 0.32 joint + 5.325 strip = 8.89 |
| Each foam insert | Cut 109.485 × 93.2975 cm from 1-1/2 in foam 2 per leaf; set 0.15 cm edge clearance |
Keep both adjoining plywood edges continuously supported by the meeting stile. Confirm the actual sheet width before calculating the strip cut width. Set a 0.32 cm movement seam; this allowance is separate from saw kerf.
Frame, trim and center connection
| Frame stile blank | Cut 213.865 cm long from 2×4 Actual stock: 3-1/2 × 1-1/2 in; 2 per leaf |
|---|---|
| Full-width frame rail blank | Cut 127.565 cm long from 2×4 Actual stock: 3-1/2 × 1-1/2 in; 3 per leaf |
| Proposed half-lap cuts | 8.89 cm long × 1.905 cm deep Complementary cuts in rails and stiles |
| Trim cuts | 7.5 cm wide from 0.236 in model stock Stiles 213.865 cm; rails 112.565 cm |
| Center cover / spacer cuts | Cover 6 cm wide, 0.236 in stock; spacer 3 cm wide, 0.118 in example stock Each 213.865 cm long before final fitting |
| Cover layout, cm | 2.4 left overlap + 0.6 gap + 3 right support = 6 |
| Gasket working envelope | 0.866 in wide × 0.118 in compressed, example only |
The modeled 0.236 in trim is not exactly 1/4 in; verify your stock. Half-laps are a replacement-frame reference; retain sound existing joints where appropriate. Final bonding, reinforcing, fasteners and hardware require selection for the actual door. Cover and spacer attach to the right leaf only.