Rustic Door using Corrugated Metal

Inspired by a changing room door at a Fatface shop, I wanted to make a rustic door for the bathroom. Here is the door that caught my imagination:


I started to make something similar, using corrugated zinc from a builders merchant and some rough wood. Oh and my new toys, an electric mitre saw, useful for cutting those triangular pieces, but also makes short work of slicing through 2″ x 4″ joists, and an electric plane. Also a glue gun, cordless drill/screwdriver, and a jigsaw. Not forgetting lots of screws of various sizes – it’s amazing how many you get through. The metal is sandwiched between 2 layers of wood, with a narrower piece between them next to the edge of the metal to fill the gap.

Tools used in this project: (All from B&Q)

Bosch Cordless Drill & Screwdriver (I have 2 of these so I don’t have to keep changing bits)

Bosch Electric Sander,

MacAllister 750W electric plane

Evolution multipurpose sliding mitre saw



Here is my version being brought to fruition (still some finishing touches to be completed)and also our Indian cupboard, which has been under wraps since we bought it 2 years ago, now in situ in the space we had reserved for it. By the time the door frame was made, there wasn’t quite enough room left, so we had to cut a piece of the door frame out, as you can see…

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Finished result, with a few screw-in studs added for good measure 🙂



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