Note: For a door-sized gate like this, you’ll need to have a doorjamb to hang it from. Alternatively, consider making a smaller waist-high version and hanging it from two gate posts.
Gather your supplies
Old panelled door
Cast-iron lacework panel, to suit
Extra cast-iron lacework border (optional)
Treated pine for rail at top of door 70 x 45mm
Cover strip round-edge moulding 20 x 5mm
Insert moulding 18 x 11mm
Dulux 1 Step Primer, Sealer & Undercoat
Dulux Design Rust (Base Paint and Rust Solution)
• The cast-iron panel must fit inside the door’s vertical panels (known as the stiles). Buy lacework panel at the same time as door to ensure their sizes match.
• Pick moulding designs to suit the door.
You’ll also need
Saw horses; tape measure; pencil; hammer; power saw; wire brush; drill; 50mm screws; power sander; dust mask and safety gear; mitre box; handsaw; clear silicone; 12.7mm wooden cover buttons; silicone sealer; angle grinder; 15mm copper saddle clips; 100mm butt hinges.
Support door on saw horses, then place lacework panel on top and mark out its shape.
Using a hammer or power saw, remove panelled section of door, where lacework panel is to fit. Use wire brush to remove as much old paint from lacework panel as possible.
To make room for extra lacework border, if using, extend size of opening in door by cutting a section out of rail at top. Cut treated pine wider than width of opening and slightly thicker than door. Notch each end so it will sit in opening flush with front of door. Position to suit size of lacework border and screw through it into back of door.
Using power sander, roughly sand back door’s paintwork to roughen surface. For safety, always wear dust mask when sanding old paint.
Measure and cut more mouldings to decorate bottom 1/2 of door, using a mitre box and handsaw. A large outer square of cover strip round-edge moulding and 2 smaller rectangular panels of insert moulding were added to this door.
For extra decoration, add wooden cover buttons to outer moulding, by drilling holes and securing buttons in place with silicone (3 per side were used here).
Paint door with 1 coat of Dulux 1 Step Primer, Sealer & Undercoat and allow to dry. Follow with 2 coats of Dulux Design Rust Base Paint, allowing 12 hours to dry after each coat. Finish with 1 coat of Design Rust Solution to create a rusted metal effect on door.
Using an angle grinder, remove any protruding sections of lacework so it fits neatly into door panel opening.
Position lacework panel and border, if using, into door recesses and secure using copper saddle clips, top and bottom.
Secure to doorjamb using butt hinges.