Step Four: Doors

I made the sliding doors out of old sheet-metal radiator covers, salvaged from a house where the radiators were being ripped out. Any number of materials could work, though the dadoes might need to be widened. Use Masonite, frosted acrylic, sheet metal, or even heavy-duty chipboard. Set the material on a scrap piece of plywood. Clamp a straightedge down. Set the blade depth on the saw to about 1/8". A carbide finishing blade (60-tooth) will cut sheet metal fairly handily (it's what I used). You can also buy specialty sheet metal blades, or use a regular framing blade with the blade rotating backwards. Wear safety glasses, tight-fitting gloves, ear muffs, and long sleeves. This process is really loud and kicks up a lot of crap. Cut eight panels, each at 13-1/2" x 22". If using a radiator screen with a geometric cut-out pattern, strive to make the cut lines fall on solid seams. Smooth down all the burrs, rough edges, and corners with a flat file and sanding block. Spray paint with metal enamel. Mount a handle at each end of each door with sheet-metal screws, made out of a scrap of 1/2" plywood.