DIY polycarbonate door

Welcome to "All about the Roof," where we discuss useful advice and guides for do-it-yourselfers who want to improve their houses. Today, we explore the world of do-it-yourself polycarbonate doors, which are a strong and adaptable choice for a range of home renovation tasks.

Because of their remarkable durability and light weight, polycarbonate doors are highly preferred for use in both indoor and outdoor environments. Polycarbonate is a contemporary substitute for conventional materials like glass or wood, whether you’re building a greenhouse, a patio enclosure, or just replacing an old door.

The resistance of polycarbonate to weather and impact is one of its main benefits when used for doors. Polycarbonate, in contrast to glass, is well-known for its strength and resilience to adverse environments like hail, high winds, and UV exposure. Glass can break and present safety hazards. This resilience makes it a sensible option for regions that frequently experience severe weather.

Polycarbonate doors are popular among do-it-yourselfers because they are simple to install. Most of the time, homeowners can install these doors without professional assistance if they have basic tools and a clear understanding of the assembly process. This reduces installation expenses and enables a personalized fit that complements unique style choices.

Polycarbonate doors also offer flexibility in design because they are available in a variety of styles and colors. There is a polycarbonate option to match your functional and aesthetic needs, whether you prefer a tinted option for added privacy and UV protection or a clear, transparent door to maximize natural light.

"Creating a do-it-yourself polycarbonate door is a cost-effective and long-lasting way to improve the appearance and functionality of your house." This adaptable material is perfect for a variety of climates because it offers superior insulation and natural light diffusion. Homeowners can create a customized door that improves energy efficiency and gives their property a contemporary look with basic tools and a step-by-step tutorial. This project lets you add a new entrance or replace an old one, giving you the opportunity to customize your room while reaping the benefits of a low-maintenance, lightweight, weather-resistant door."

DIY polycarbonate sliding doors – the whole process of creating

Up until recently, polycarbonate was used to make visors, greenhouses, shower booths, and other structures. However, with today’s technology, you can construct sliding doors with polycarbonate by hand that look incredibly fashionable and update the interior of your home. A wide range of colors are available for polycarbonate sheets, making them appropriate for any type of design.


The following are some of polycarbonate’s benefits:

  • lightness, a sense of airiness;
  • higher reliability in comparison with glass;
  • safety – with a crack, it does not scatter into small fragments;
  • Simplicity of care.

With these qualities, polycarbonate sliding doors will last a long time and amaze their owners with their strength.

Doors are available in two configurations: sliding and suspended. The second choice is the most typical. Sliding doors feature a compartmentalized design. That is to say, their sash reaches the wall. You must choose whether or not to include a frame when creating these doors. Structures made of plastic, wood, or metal are frequently used as frames. A frameless door is made entirely of polycarbonate; no other materials are utilized in its construction.

In order to create a sliding door without a frame that looks much richer, you must first realize that creating a door without a frame will cost a lot more in materials than creating one with a frame. The material is elementary, but there are no manufacturing challenges.

  • electric drill and drill;
  • screwdriver (screwdriver);
  • roulette and level;
  • cutting machine (jigsaw);
  • The square.

Should the door be framed, you need to have:

  • polycarbonate canvas (you can pieces finished in size);
  • corners made of metal or polymer (for the opening);
  • self -tapping screws and corners for fastening the frame sides;
  • Fasteners for the box.

Polycarbonate sheets and a single fastener are used to attach doors without frames.

Phases involved in making a polycarbonate sliding door

  1. The opening is measured taking into account the fact that the frame is made less than the opening for one and a half centimeter in order to close tightly and not touch the box.
  2. With particular thoroughness, the rectangle of the wooden opening is measured with the help of a square. If you allow errors at this stage, then the door simply will not enter the opening. For metal and plastic, this is not necessary.
  3. Bars of bars are collected using metal corners.
  4. The assembled frame of their tree is polished and treated with varnish (or stain) for aesthetic appearance.
  5. Keep in mind that the frame can be made with the help of an old canvas on which the bars are placed around the perimeter and the necessary measurements are made. Then, with the help of a jigsaw, the assembly of the frame is made and the polycarbonate sheet is attached with self -tapping screws.
  6. For greater aesthetics, self -tapping screws with decorative hats are used.
  7. After the frame and the box, the canopies are attached to the frame and, finally, the structure itself is mounted.

Because the material is lightweight, even one person can complete this work. The frameless option is even easier: the desired size is cut out after a polycarbonate sheet is applied to the old door’s canvas.

The following instruments are required to assemble the sliding doors:

  • Polycarbonate canvas five to six centimeters more than an opening;
  • Direct pipe of double -width of the opening;
  • fasteners and anchors;
  • List of previous materials.

First, a retractable structure called a guide is installed. Five or ten centimeters above the opening is where the tube is mounted. Half of it is fixed over the door opening, and the other half is moved along the plane in the direction that the door moves.

Following that, the polycarbonate sheet is affixed with rings. Fasteners are used for this. To move the door along the guide, they are screwed. The distance between the door and the floor should be 0.5 mm. The canvas is lowered just below the threshold when it is present. The doors will be able to be closed more firmly as a result.

At the ends, restrictions are placed. The rings containing the polymer are hung on the guide in this instance. The handles are fastened to the sheet if necessary. We can declare that your home now has a contemporary, fashionable door that is safe and long-lasting once the door handle mounting is complete! You should also feel proud because you made the doors yourself!

These days, polycarbonate material is among the best—if not the best—for putting the most audacious ideas into practice. In addition, the price of purchasing the materials and installing the door is very low! Grab a daring instrument.

Please carefully read our article to learn how to make sturdy doors on your own if you want to make high-quality polymer doors.

Polycarbonate doors: how to make

Polycarbonate’s remarkable appearance, low weight, and cheaper cost when compared to glass make it an appealing material for filling door leafs as well as for building verandas, greenhouses, transparent roofs, and partitions. What exactly is this polymer material, then?

However, he does not beat or scatter on the pieces, protecting the functioning of structures from it. Furthermore, it is incredibly simple to make polycarbonate doors by hand compared to other options. This is the subject matter covered in the article’s video, and a theoretical section will provide additional details.

Glass substitute: polycarbonate

An engineering synthetic sheet material that can function at sufficiently high temperatures is polycarbonate. As a result, it works well for both street structures and premises; all you have to do is select the appropriate one.

Qualities and benefits of the substance

Naturally, polycarbonate cannot be substituted for glass in windows, for example, because of its different translucency. However, because of its adaptability, it aids in the creation of intriguing designs with curved forms, such as sliding canopies over a patio or swimming pool.

There are two varieties of polycarbonate, with their distinct structures serving as the primary distinction:

  • First option – These are thin double panels interconnected by jumpers that form cells in the thickness of the material. Because of this, this type of polycarbonate was called "cell".
  • Another variety polycarbonate, due to a continuous structure, is called monolithic. In appearance, sheets are very similar to glass, and can have a thickness of 0.2 to 2 cm. They are almost as transparent, which can be seen even in the photo, so it is the panels with a monolithic structure that are most often used to build partitions and glazing interior doors.

The cellular polycarbonate, which can even be rolled, performs better than the monolithic sheet; however, if needed, hot molding can be used to give it a spherical shape. The material has a higher strength and can even function as a frameless self-supporting overlap because of its dense structure.

2.05 meters is the standard width of the polycarbonate sheet. Although the length can vary greatly, it is at least 3 meters. Rich color scheme of the material also contributes to its popularity.

It can have a bronze hue, be matte or transparent, or be every color in the rainbow. Although manufacturers typically promise to maintain quality for ten years, polycarbonate lasts considerably longer.

Svetlar doors

Polycarbonate can be used as a filler for folding or sliding doors, or it can be placed into the canvases of hinged open doors. The latter are mounted in the floor or move on rollers along the guide rail above the opening, while the former are fastened to the slopes using loops.

It is possible for the polycarbonate door paintings to be performed without frames. In this instance, the polymer sheet serves as the frame, and all of the accessories are fixed to it. It is obvious that polycarbonate alone should provide the structure’s stiffness in the absence of a frame. In these situations, only a sufficiently thick monolithic option is employed.

Though expensive, this type of door has a very sturdy appearance. Cellular structure sheets are only used to fill wooden, aluminum, or plastic frames because they are too light and less sturdy for frameless doors.

Construct a frameless polycarbonate door; while this is nearly impossible to do at home, it looks dignified when inside. Unless it’s going to be a pantry or closet cape door.

Only the wood option is appropriate for independent work if you prefer the frame method. Simultaneously, polycarbonate assumes the role of glass and is commonly inserted into the frame by fastening fragments that have been cut to the appropriate size.

  • Basically, our readers are interested in the question: “How to make doors in a greenhouse with polycarbonate?". For this, you just need instructions for the installation of this material, which can be found without difficulty. In principle, it will be required if the whole greenhouse gathers from the polymer sheets. As for the door, then the main task is to correctly make a canvas frame so that it fit into the opening.

Note: If the greenhouse was constructed independently on a metal frame rather than as part of a factory, the canvas frame needs to be made of metal. You can use an aluminum profile pipe that is 30/2 mm or 40/3 mm in size to accomplish this. If the greenhouse is made of wood, it is best to use a pine beam with a 50*50 mm cross section for the door frame.

  • Then the frame on one or two sides is sheathed with cellular polycarbonate. To ensure timely condensation outflow, the sheets are oriented so that the longitudinal channels are located in height of the door. The material itself is quite easy to process. Cut it with an ordinary hacksaw, and before installing the fasteners, pre -drill holes.

It is best to divide the door leaf’s frame in the middle with a cross face—preferably two—for improved stiffness.

Therefore, the door skin can be assembled from two pieces, and they can do it on the middle, if you do not have a solid sheet of polycarbonate that matches the frame in size. The greenhouse door’s canvas frame is fastened to the racks using loops, and the spinaglia is screwed in from both the inside and the outside.

However, he does not beat or scatter on the pieces, protecting the functioning of structures from it. Additionally, construct polycarbonate doors by hand.

How to make doors from polycarbonate: master class

Most frequently, polycarbonate is used in summer cottage construction for awnings, visors, and greenhouses—the structures that require the greatest amount of material. Today, though, a fresh approach to design has emerged: the use of these reasonably priced, yet fashionable, and dependable interior doors.

The greenhouse door

Using polycarbonate

Prior to the designers creating their own line of exclusive products, showers were frequently made of polycarbonate. Given that these plates make such products far more easily than other materials, it was incredibly practical and convenient. For instance, this material is far safer and easier to work with than glass.

There are two kinds of polycarbonate doors:

The initial variant appears more conventional. Awnings that are housed inside the box are used to attach these designs. One or two sashes are available in the second type, which is a compartment option. These sashes open parallel to the wall’s plane.

Additionally, interior door structures are classified into another category as follows:

  • frame;
  • Carious.

The shape of a frame is created by frames. As demonstrated in the video, you can install a polycarbonate plate with your hands. The frame in this instance may be made of plastic or metal. Experts advise using poplar wood for a wooden frame because this breed is relatively light.

The second kind, known as frameless, is associated with a particular, privileged group. These doors consist entirely of a polycarbonate sheet, with a solid frame supporting the sheet. Financial costs are significantly higher than in the previous instance because they appear both richer and stricter than before.

Production process

You’ll need a variety of equipment and supplies to create these items by hand. Since processing polycarbonate doesn’t need to be done in great detail, specialized equipment doesn’t need to be stocked. There are sufficient instruments, like:

  • electric drill (plus a set of drills of different sizes);
  • ruler and roulette;
  • a machine designed for cutting material at an angle.

The type of structure will determine what details are required. Self-tapping screws, plastic or metal corners, and other materials can be used. The only preparations needed for a frameless structure will be for a polycarbonate sheet and multiple awnings.

This is how the manufacturing process is executed. Measure the opening where the design is going to be installed first. You must construct a frame and reduce its size by about 1 mm based on the computation results. To ensure that the structures are securely closed, this is required.

When building the frame, pay close attention to the corners. They should be perfectly straight to avoid any distortions similar to those in the picture. Metal corners are used to pull the completed frame together for this purpose. The material is varnished before the structure is wrapped in casing. In this instance, meticulous polishing of all surfaces—interior and exterior—is necessary. Stain is an option for use when painting.

If the old door’s records are still in existence, it is advised to use them as a foundation to streamline the computation of the new one. The canopies are made after the frame, which has been meticulously prepared, is covered in polycarbonate. As seen in the picture, they must be immediately fixed with your own hands on the doors and then on the box. The installation of the door itself is the final step. This design can be completed without assistance because it is significantly simpler than the others.

Sliding structure installation

Compared to hinged structures, sliding structures are a little more complex. In order to construct it manually, you must install the guide mechanism depicted in the picture. The doors will slide along the walls because of him. Among the benefits are worthy of mention:

  • minimum area in the room in open state;
  • Reliable insulation (in the event that the device is single).

In the manufacturing process, anchors and unique fasteners will be required. Additionally, a metal tube that is fixed 7–10 cm above the opening is required. Next, the polycarbonate sheet needs to have a few rings attached to it. They have to follow the guide. They must be adjusted in the tube as the picture illustrates in order for the sheet to be positioned at a mark 1.5 mm above the ground.

Numerous additional benefits of the sliding structure raise the room’s comfort level. For instance, because of the way the wings are made, these products can’t close on their own and are also quite simple to open. Additionally, an automated sliding structure is possible owing to contemporary technologies.

Polycarbonate door designs

The use of polycarbonate in the design of internal premises interiors has been made possible by its appealing appearance, extensive color selection, and ease of processing. Polycarbonate It is employed in the installation of furniture components, interior partitions, and screens for zoning interior space.

Lately, polycarbonate doors have become increasingly common. The following traits of the synthetic polymer door leaf are present:

  • Extraordinary lightness. Thanks to this, the installation process of structures becomes convenient and simple;
  • The synthetic polymer is very durable, which affects both the convenience of installing the door structure and on the convenience of its further operation;
  • High degree of safety. Even in case of damage, polycarbonate does not form traumatic fragments and does not scatter like glass;
  • Widespread possibilities for design. Depending on the type of polycarbonate, the door can be completely or partially transparent, have different colors and shades. If necessary, you can choose a matte version of the material.

Types of polycarbonate doors

The doors made of synthetic polymer can be hinged or sliding depending on how the opening mechanism is opened. Awnings are used to secure the door leaf to the jamb using the hinged structure. Sliding doors use a unique guide mechanism to open and close parallel to the wall.

Polymer-based doors come in both frameless and framed options.

The frame with the frame implies the existence of a polycarbonate glazing frame. Wood, plastic, or metal can all fade. The frame should be the easiest to work with while still guaranteeing the door structure’s rigidity. Combining polycarbonate with aluminum profile frames works well.

There is no frame in the frameless structure, correspondingly. In this instance, the polymer sheet is directly attached to all hinged components and accessories. Typically, a monolithic polycarbonate is used for the frameless door device to ensure rigidity and provide the design with the necessary weight. Although this door design is more expensive, it appears rigid and strong.

Making doors made of polycarbonate independently

It doesn’t take a lot of carpentry experience to make polycarbonate doors by hand. The contractor just needs to carefully carry out a few basic procedures because polycarbonate is an easy material to work with.

How to assemble and install a hinged door

Determining the precise dimensions of the building is the first step in the manufacturing of a hinged door. The process is made easier if a polycarbonate door is to be installed in exchange for the old one because the old door will be used as a template to make the new one. If this is the first time the door is being installed, precise measurements must be taken first. It is important to keep in mind that in order to guarantee the opening and closing process, the door’s dimensions should be 1-2 mm smaller than the opening’s size.

Once the size has been established, the door structure’s frame can be manufactured. To prevent distortion and door jamming during subsequent operations, it is imperative to strictly withstand straight angles when assembling the support frame.

If the frame is made of wood, pulling the corners with special metal corners will give the structure the necessary stiffness. After the frame is assembled, its surface needs to be carefully polished, painted, or coated with colorless varnish.

Polycarbonate can be affixed to the frame in one layer at the center or on both sides. The door will be more rigid with double-sided fastening, but the material placed in the middle of the frame will look far more beautiful.

Using an aluminum profile as a frame works best for adhering polycarbonate in a single layer. Attaching the awnings, handles, and lock is required after the polymer material has been installed. The lightweight nature of the polycarbonate door makes installation on the canopies a straightforward process.

Because more details and accessories are needed, designing and installing doors with a sliding scheme is, on the one hand, a more involved and costly procedure. However, practically every detail of this system comes in a set, and the installation procedure is highly technological and breaks down into multiple carefully regulated steps.

The sliding doors’ operating mechanism is exactly the same as the wardrobe doors’ operating mechanism. The system is made up of the lower rail, which the door moves along with the aid of support rollers, and the upper guide, which keeps the door leaf upright. Some sliding system designs have the door leaf suspended from the upper guide and no lower rails.

The horizontal installation of the upper and lower guide systems during the installation of sliding type doors requires particular attention because it affects the mechanism’s overall future functionality.

The instructions for a specific set of parts must be followed when installing accessories on the door leaf. The roller spring system for fixing the door leaf in the upper guide, support rollers or wheels for installing the door on the lower rails, fixers, and door limiters are generally included in the sets, though the exact contents may vary.

The door leaf must be adjusted after the sliding door is installed from polycarbonate to the guides. Special screws that are incorporated into the lower support roller design are used for adjustment. You must rotate the screws to remove all of the door leaf’s distortions and bring it to a level position both vertically and horizontally.

Every owner can easily create and install polycarbonate doors with their hands because they have a stunning, robust, and lightweight design.

Materials Needed Polycarbonate sheets, measuring tape, marker, circular saw, drill, screws, hinges, door handle, weather stripping
Steps 1. Measure and mark the polycarbonate sheet according to the door frame size. 2. Cut the sheet using a circular saw. 3. Drill holes for screws and hinges. 4. Attach hinges and door handle. 5. Install weather stripping around the edges for sealing.

Constructing a do-it-yourself polycarbonate door for your roof can be a satisfying project that improves appearance and functionality. Selecting polycarbonate means that you are going with a material that is renowned for being both lightweight and durable. These doors are multipurpose and provide good weather resistance with the flexibility to let in natural light. Careful measuring, cutting, and assembling are required whether you’re installing a new door or replacing an old one.

To guarantee a precise fit, start by taking accurate measurements of the door frame. Although polycarbonate panels are simple to work with, they need to be cut precisely with instruments like a handsaw with fine teeth or a circular saw. After the panels are cut to size, fasten them into the frame with the proper fasteners, making sure the seams are sealed tightly to avoid gaps. If you want better insulation and weather resistance, think about adding weather stripping around the edges.

You can add your own flair by customizing your polycarbonate door. To adjust the amount of light transmission and privacy, you can select various panel thicknesses and tints. Furthermore, polycarbonate doors are easier to handle and install because they are lighter than more conventional materials like metal or wood. It usually only needs to be cleaned once in a while with a mild soap and water solution to keep it clear and stop dirt accumulation.

Learn about local building codes and regulations before beginning your do-it-yourself project, particularly if the door is part of an enclosed space or has an impact on the structural integrity of your roof. To protect against sharp edges during cutting and installation, safety goggles and gloves are necessary. Your DIY polycarbonate door can be an affordable, aesthetically pleasing, and long-lasting addition to the roof of your house with careful planning and attention to detail.

What do you think, which element is the most important for a reliable and durable roof?
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Denis Shcherbakov

Professional roofer with 20 years of experience. I know everything about the installation, repair and maintenance of various types of roofs. I will be happy to share my knowledge and experience with you.

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