Build It | Salvaged Door Shadow Box

Transforming old, discarded materials into beautiful, functional pieces is a hallmark of sustainable home improvement. In this project, we’ll show you how to repurpose an old door into a charming shadow box, perfect for displaying cherished memories or decorative items. In the video above, This Old House general contractor Tom Silva and host Kevin O’Connor demonstrate the process.

*Unless otherwise noted, costs in this article reflect an average of prices that our team found from hardware stores like Lowes and Home Depot, and on Amazon.com.

Necessary Materials To Build a Shadow Box

Before you can start on this project, you’ll need a few items in addition to your old door, including:

• Brad nailer
• Bucket of water
• Circular saw
• Danish oil
• Glass
• Glass cutter
• Miter saw
• Palm sander
• Permanent marker
• Polyurethane glue
• Rags
• Sandpaper (medium-grit)
• Safety gear, including safety goggles, gloves, and a P95 or higher-rated mask
• Spray bottle
• Strap clamp
• Table saw
• Tape measurer
• Wood glue
• Wood putty

How To Build a Salvaged Door Shadow Box

Here are the steps you need to follow to break down the old door and build your new shadow box. Make sure you use appropriate safety gear for each step.

1. Check for Lead Paint

Older doors may contain lead paint, which can be hazardous if not handled properly. The older the home, the more likely it is to have lead-based paint. You can test your door (and your home) by using a lead paint test kit that you can purchase from your local home center. If your door has lead paint, you will need it professionally removed.

2. Break Down the Door

To break down the door into usable pieces:

1. Use a circular saw to cut the door into smaller sections, using the stiles and rails as guides.
2. True up the sides of the boards using a table saw for clean, straight edges.
3. Remove any remaining stain or paint using the table saw, making two passes on each side of each board.

3. Prepare the Frame Pieces and Back Panel

Next, you’ll need to start creating the actual frame pieces. Using a table saw, make a rabbet cut on the inside edge of the stile to hold the back panel. On the opposite side, create a dado cut to accommodate the glass. Don’t cut it down to size just yet. 

One of the door’s recessed panels will be used to create the back panel of your shadow box. Sand it down to create a smooth surface.

4. Fill Any Imperfections

Fill any holes or imperfections with wood filler made from a mixture of wood glue and sawdust from your earlier cuts. For larger holes, install scrap wood fillers before applying the wood putty. Once the filler is dry, sand the entire panel and stile with medium-grit sandpaper for a uniform finish.

5. Apply the Finish

Apply a Danish oil finish to the frame piece to prevent oil from getting on the metered edges. Allow it to dry completely and remember to dispose of any oily rags in a bucket of water to avoid spontaneous combustion.

6. Cut the Stile and Back Panel

Once the finish is dry, you can cut the prepared stile into four pieces of equal length using a miter saw. Cut the ends of each piece at 45-degree angles to create perfect corners when assembled.

Using the measurements from the boards, you can cut the backer down to size using the table saw.

7. Cut the Glass

To cut the glass:

1. Lay the back panel on top of the glass and use a marker to trace the edges of the panel onto the glass.
2. Use a glass cutter dipped in oil to score the glass along your marked lines.
3. Turn the glass over so the traced line falls just over the edge of your workbench. Lift the glass and snap it gently down onto the table. This should break the glass along the line.

8. Assemble the Frame

In order to assemble the frame, you need to:

1. Apply polyurethane glue to the mitered edges of three of the four frame pieces.
2. Secure three of these pieces together using brad nails.
3. Slide the cut glass into the dado cuts of the assembled pieces.
4. Attach the fourth side of the frame, completing the box.
5. Use a strap clamp around the entire box to secure the piece while the glue dries.

9. Attach the Back Panel

Once the glue has set, place the back panel into the rabbet cut on the frame. Secure the back panel using small wood screws, making sure they don’t protrude through the front of the frame.

10. Customize Your Shadow Box

Now that you’ve constructed your shadow box, it’s time to make it your own. Here are some ideas for personalizing your creation:

• Choose a paint or stain color that complements your decor.
• Add decorative molding to the frame for extra flair.
• Install hooks or pins inside the box to hang lightweight items.
• Use fabric or decorative paper to line the back panel.

Maintenance Tips

To keep your shadow box looking its best for years to come, follow these maintenance tips:

• Dust regularly with a soft, dry cloth to prevent buildup.
• Clean the glass periodically with a non-ammonia glass cleaner.
• Check the back panel screws annually and tighten if necessary.
• Avoid placing the shadow box in direct sunlight to prevent its contents from fading.
• Handle the shadow box with care to avoid damaging the wood or glass.

Our Conclusion

Repurposing old materials reduces environmental impact while providing unique and personalized items for your home. Whether you’re a seasoned DIY enthusiast or a beginner looking to start small, this shadow box project offers a practical way to hone your skills, create something beautiful, and make use of an old door. If you enjoyed creating a shadow box from a salvaged door, you might want to consider using reclaimed wood to create bar stools, milk stools, shelves, coffee tables, and more.

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