I bought some select pine 1x4's and two sheets of 5.2mm Luan (esentially 1/4 inch) I also bought a big piece of foam insulation to use as my work space and to keep everything off the concrete.

I cut the select pine pieces to my desired door size and layed them out with the square.

I glued the seam where the boards touch and then put two staples on the board to hold it together. The piece of paper was so the excess glue wouldn't stick to my sheet of luan.

I waited a day for the glue to dry and then put angle iron pieces on all corner angles to strengthen the frame. Instead of doing what I did. You could have used dowls.

A shot of the door with all angles secure. Now I am placing a center piece of wood for added strength.

Here is a picture of a the completed frame. Its is very sturdy with the glue, staples and angle iron

Next thing I did was cut the luan side panels. I actually made the side panels a tiny bit bigger than the frame. I will use a router with trim bit to flush the sides.

I then clamped the piece I cut and then traced it with a pencil to get the outline for the other piece of luan to form both sides of the door.

Stuck a trim piece on the frame.
This picture sucks

The 1x4 select pine is actually only 3/4x3.5 inches. The Luan is a 1/4 inch. If I stuck the side panels on the frame I would only have a door that is 1.25 inches thick. I've never seen a door knob this skinny before. Most door knobs will do 1 3/8 to 2 inches. I decided to put spacing on both sides which would give me an end result of 1.5 inch thick door. With the excess pieces I had left from cutting the side panels from the Luan, I ruffly cut, glued and used brad nails (5/8 inch) to secure them to the frame. I also left over hang on these spacers.

A blurry picture of the spacer piece over hanging the frame

Another picture of the frame with spacer on oneside

Air tools rule. This is a little brad nailer I've had for a couple years. I got it at Walmart for $20 and it works great. I am sure many china men slaved for Penny's to build this nail gun for me.

I put the center spacer on. You will notice that its not very straight. Doesn't need to be either :-P

Glue which I put under every spacer

Here is the frame with spacers on bothsides

Router Time! I used a trim bit to rip the overhanging edge of the luan trim pieces to be flush with the frame.

I got tired of working on the door and decided to hang up my 2x4's for the ruff opening. I used a crap ton of liquid nails and some tapcon screws

I glued and brad nailed one side piece of luan to the frame.

I flipped the door over

I squirted white sticky stuff all over the inside of the door

Now I am sticking 3/4 inch foam insulation into it. This will help with noise and make the door feel a little more solid.

All foam is inserted into the door.

Another picture of the door with foam in it.

I glued, brad nailed the other side panel on. Then I used the router just like I did with the spacer pieces to make the side panels flush with the frame. Then I used my little mouse sander to smooth out any burs left from the router.

I propped the door up on saw horses and then decided to prime it. You could stain it if you wanted but my wife likes white doors and white trim. So this door will be white.

The door is primed. It actually looks like a door now too!

Hung the other side of the framing up

bottom part of frame

Frame again