Construct a Sauna Entryway
Building a custom sauna door provides the perfect final touch to a home sauna. With some basic carpentry skills and the right materials, you can create a beautiful and functional portal into your personal steam sanctum.
A sauna door has some unique design considerations compared to standard interior or exterior doors. The high heat and humidity require durable construction from wood that can withstand extreme conditions. Cedar is an ideal choice. The door itself will be smaller than typical in order to keep the heat trapped inside. And aesthetically, the design should match the rustic simplicity of the sauna overall.
Gather Materials for Constructing a Sauna Entryway
The first step in this woodworking project is gathering the necessary supplies. Basic sauna door materials include:
- Cedar or redwood boards for the frame
- Plywood panels
- Hinges
- Handle latch
- Weatherstripping
- Wood glue
- Nails or screws
- Sandpaper
- Protective wood finish
In addition to these basics, you may want glass for a window into the sauna. Some other optional supplies depending on door design are insulation, aluminum sheathing, and wood trim or molding.
For tools, you'll need measuring tapes, a saw (table saw, miter saw, jigsaw, or handsaw), drill, screwdrivers, clamps, safety equipment, and materials for finishing like brushes and stain.
Size and Design Considerations
Sauna door dimensions are smaller than average. The standard interior door size is 30-36 inches wide by 80 inches high. An appropriate sauna door size is typically 24-28 inches wide by 72 inches high. This compact size contains heat while allowing easy entrance and exit.
Wood choice matters due to heat and moisture conditions. Cedar heartwood has natural preservation oils that resist decay. This fragrant softwood is lightweight, easy to work with, and stains well.
Design the inner door layer from moisture-resistant wood or plyboard. Ensure the opening direction is outward for safety precautions. Add a window for functionality or aesthetics, either with basic glass cut to size or ordered to specification.
Tools for Building a Sauna Entryway
Essential tools for sauna door construction include:
- Measuring tape
- Miter saw
- Table saw or circular saw
- Jigsaw
- Router
- Drill
- Brad nailer and compressor
- Sanders
- Safety gear like goggles, respirator, and ear protection
Nice-to-have tools that simplify the work are a compound miter saw, band saw, joiner, planer, and clamps. With attention to detail in planning and cutting, though, you can build an attractive custom sauna door with simple hand tools.
Measuring and Sizing Lumber for the Door
The foundation for a durable and well-hung sauna door is an accurately constructed frame. Follow these steps for measuring and cutting sauna door frame pieces:
- Determine the final door width and height based on rough opening size. Allow a 1-inch gap on all sides for adjustments during installation. For example, a 28'' x 72'' door would have a 26'' x 70'' frame.
- Cut the vertical jambs and horizontal header and sill to length from 1x4, 1x6, or 1x8 cedar lumber with a power miter saw.
- Cut 1x2 furring strips to make brick molding trim pieces that will overlap the door jambs.
- Cut pieces for the door panel front and back from moisture-resistant plywood or pine at your determined height and width.
Creating Custom Sauna Entryways
For a more custom finish, use thicker cedar boards up to 2x10 size for the jamb framing and ash or maple plywood for the inner door skins. Solid wood options like alder, aspen, maple, ash, or oak work as well. This allows you to shape or route design elements into the wood.
Custom sauna doors often have a large glass window, especially for outdoor sauna rooms. This allows enjoying the outdoor view from inside the steamy sauna. Use tempered safety glass and a moisture-resistant wood frame around the window.
Now for constructing the actual sauna door...
Assembling the Door Frame
With pieces cut to specifications, it's time for assembly. Follow these instructions to construct the cedar door frame:
- Sand edges and ends of the board frame pieces. Break sharp edges.
- Apply exterior-grade wood glue on ends and joints.
- Align frame boards together and clamp tightly.
- Drill pilot holes through the frame from each side to prevent wood splitting.
- Drive in 2-inch galvanized finish nails or stainless steel screws at an angle through the pilot holes to reinforce joints.
- Allow the glue to cure fully before removing clamps. Then sand any dried glue squeeze-out.
- Insert wood shims along the sides and top to temporarily brace the frame.
Check for square by measuring diagonally across the corners. Adjust as needed until measurements are equal. Allow to fully cure overnight before handling further.
Wood Selection for Sauna Doors
The best woods for steam room doors balance stability, strength, appearance, and affordability. Good options include:
- Cedar - Naturally resistant to decay, weather, and insects
- Redwood - Dense, durable softwood for exterior uses
- Cypress - Stable wood from coniferous trees
- Douglas Fir - Affordable and attractive softwood
Stay away from open-grained woods like oak or ash that absorb moisture. Exotics like teak are beautiful but expensive. Pine is prone to warping. For most home DIY sauna doors, knotty cedar offers an ideal blend of functionality, beauty, strength, price, and ease of installation.
Mounting Sauna Door Panels and Hardware
With a squared frame built, it's time to add the door panels and hardware. Follow these instructions:
- Glue panels made from moisture-resistant plywood or boards into the door frame front and back, leaving space for glass if including a window. Clamp until the adhesive dries.
- Install door hinges according to manufacturer specifications. Test fit the door into the rough opening for swing clearance.
- Bore holes for the door handleset, latch, and strike plate based on the included hardware templates.
- Add the handleset, latching mechanism, and slide-on strike plate to test function.
- Install flexible adhesive weatherstripping tape around the door's back edges to seal gaps when closed.
- Finish smooth door faces and surfaces with protective stain or varnish.
Performing these assembly steps creates a stunning and durable sauna portal ready for installation as the final steam room accent. Breathe deeply, relax slowly, and get ready to de-stress in style.