Easy Flat Panel Door Makeover

Easy Flat Panel Door Makeover

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I must have this thing for doors lately... I just finished redoing the front door and now this bathroom door. To see the front door makeover, click on over to 1960 Front Door Makeover. It came out so great!!

Anyway, the real reason I finished the bathroom door, was because it was the last project to finish our guest bathroom and hubby's been wanting me to FINISH projects! ๐Ÿ˜œ ๐Ÿ˜

I'm so glad I did too! I wasn't too sure how many panels to do on this door, but in the end we thought that 2 panels felt right for this house. Practically all the doors in this house are flat panel, so I'll be doing this treatment to all of them... eventually.

It's a pretty simple process. This door was painted on one side and stained on the other. I quickly sanded both sides.

Flat panel door

If you've followed me for awhile, you'll know I've used underlayment for all the shiplap projects we've done. (You can check out the list below) It's cheap and easy to work with. Even with the rising cost of lumber this year, it still was only about $15 for a 4x8 ft. sheet. 

Shiplap Accent Wall
A Cheap And Easy Way To Make A Sign
Shiplap The Office
Cheap & Easy Shiplap

So, Hubby and I picked up some underlayment at Lowes. The first thing we did was rip the big sheet in half lengthwise. This made it much easier for me to cut the rest of the strips out by myself. ๐Ÿ‘

Here are the measurements for the underlayment strips I cut. Then I dry fitted them on the door.

Measurements for underlayment strips on door

I did this to both sides of the door. To adhere them to the door, I used Gorilla Wood Glue and my trusty Ryobi Airless Nail Gun. Using clamps also helped keep the pieces in place. 

Attaching underlayment strips to flat panel door

You want to make sure that your edges are all even and flush with the edge of the door. 

*Note - Don't forget to recut your door knob hole. After one side was finished, I flipped the door over and cut the door hole with a hole saw. It was easy because there was already an existing hole.

Then I filled all the joints with wood filler and caulked inside the panels with a paintable caulk.

Wood fill joints and caulk panels

The other thing I had to do while the wood filler was drying, was to cut away the excess wood from the door hinge. I used our Dewalt Oscillating Multi Tool for that simple little job.

Cut excess wood out from door hinge

Once the wood filler was dry, I sanded everything down with my favorite sander, Dewalt Oscillating Sander. It made quick work of making everything smooth. 

Then it was time for paint! That's the super easy part! At this point, there are 2 coats of primer on.

Prime & painting door

Then 2 coats of paint and let's hang this door. 

Before we get to that, I had to fix the size of the door hole. Apparently, older door knobs were much smaller. We had to do this same thing to our front door.

Anyway, this Ryobi Door Hole Saw Kit, is a lifesaver! It's super hard to 're cut' holes without some sort of guide to keep the hole saw in the correct placement. 

Fixing Door hole size

Yay! It's all done! I picked up this black door knob on Amazon. 

New door knob installed

I had a question asked about the thickness of the door. Here you can see the underlayment added, but it's only slightly noticeable.  I just sanded the sides and painted.

Thickness of door

What a difference!! I love how it came out!

Flat Panel Door Makeover

There is just something about this craftsman trim and the door that just makes me smile! ๐Ÿ’—

Craftsman Trim and door



  1. Would you mind showing a picture of the side of the door? Wondering how it looks being thicker and with raw edges on edge-how can you conceal those? thanks!

    1. This comment has been removed by the author.

    2. Great question! I sanded the edges and just painted it. You can see the that underlayment was added, but it is only slightly noticeable. I've added a photo so you can see.
      Thanks for reading!

  2. Did you have to move the door stops since the door thickness chaged?

    1. Yes! I did. They were simple to remove. Close the door and reattach. Great question!

  3. How thick was the underlayment you used, anyone know?

    1. Great question! The underlayment is just about 1/4" thick. I buy it in big 4'x8' sheets and cut it to size.

  4. It seems that if you thickened the door, it wouldn't fit back in right and the latch wouldn't catch. How did this thicker door get reinstalled so well with what looks like hardly any issues?

    1. Great question! We took off the door stop which is the piece of trim in the doorway that stops the door. Then reinstalled it to adjust for the thickness of the door. There was a little play in the latch and we slightly moved that. It was amazing how it all worked out!

  5. What door handles did you use with thicker door?

    1. The door handles were just from Amazon. They weren't special. You may have to adjust the hole where the door latches closed.

  6. These look amazing! Can I ask how many doors you could get out of one sheet of plywood?

    1. Hi Jilli! Well, I'm not too sure, definitely more than one door, if not 2 or 3! I have the whole house to do yet. However, I'm knee deep in a kitchen remodel. We'll eventually get to the rest of them.

  7. Do you remember how long this took you and how much the materials cost? It looks really good!

    1. Thank you!! Hmmm... well, it doesn't really take long, maybe a day or two. It's just the process of cutting the wood... gluing/nailing/drying. Then painting. The sheet of underlayment is about $22, and I could definitely get more than one door out of it. Plus glue, and paint. So much cheaper than buying a paneled door!


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