When it gets cold, your pet doesn't have to be stuck outside when you're not around to open the door. A pet door can allow cats and dogs free access to the warm house and the great outdoors. If you're tired of playing doorman for your pet, or aren't home often enough to give him or her the freedom and shelter required, a pet door is an excellent solution. You can buy many different types of pet doors commercially, from the simplest flaps to elaborate electronic doors, or you can make your own.
Building a weather tight pet door isn't difficult, as long as you have the tools and a few skills. If you're lucky, you'll even be able to make it for ten to twenty dollars, instead of the fifty and up that you'll need to spend for a quality commercial pet door. Here's how to do it.
You'll need a few things to build your pet door. The main component is a set of floor mats, meant for using in the back seat of a car. These can be made out of rubber or vinyl, and are usually around 13” x 16”. This is fine for small dogs and cats. If you have a larger pet, you'll need larger mats, such as those sold for the front seats of cars, at around 16”x28”. Look for mats that don't have bulky embossing.
You'll also need two strips of sheet metal in a medium gauge, and some magnetic ribbon. A piece of canvas or vinyl around 6”x36”, forty inches of 1 1/8” corner molding, a 12” aluminum strip, a piece of masonite, and a few screw and clips finish out the materials list. These materials are for a hollow or solid core door between 1 3/8” and 1 3/4” in thickness. For a panel door, make sure that the inserts are sizable enough to accommodate the mats you're using, and use 1” trim instead of corner molding. Also, exchange the screws for bolts. You won't need the fabric.
A drill, hoe saw, utility knife, keyhole saw, jigsaw and scissors are the tools needed, as well as some upholstery cement and sandpaper. If you don't own these, it's possible to rent them. Make your initial hole somewhat larger than the inner flap (floor mat), so that there will be an exposed wooden lip at the bottom. Experiment with dimensions before cutting. You'll need to cut your mats to the desired size before you choose the dimensions of the door opening.
Once you've joined the mats together, creating an inside and outside flap, you can then glue a piece of magnetic ribbon to the lip of the in-facing flap. Fasten two metal strips to the inner face of the outside flap. Then, if you're using a solid core or hollow door, use the upholstery cement to fasten fabric over the exposed core of the door. Make sure that there's an inch of overlap on the interior face, and several inches on the outside. You'll cover this with molding later.
Then, line up the mat assembly with the opening, allowing the inner flap to move freely. Fasten it with a series of wood screws a few inches apart, then cover the area with the aluminum strip, so it will act as a rip-stop. Finish the outside of the door by gluing magnetic ribbon over the fabric that's exposed at the lower edge of the passage. Trim can now be used to cover the inner fabric. Install clips over the trim, so that the hardboard or masonite can be slipped down behind them to block the door when you don't want it to be used.
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