Sealing door and drilling holes for fans

I got my hands on a piece of trash bookshelf. I have built a door for it. All I need to do is put the hinges up and she is ready to be turned on.

Before I can turn her on, I don't know how to seal off the door. I used caulk in every other crack and corner, but realize I cant caulk the door shut and couldnt apply caulk to do the door while it is shut anyway. What is the next best way to seal off the door for light and smell?

Second question. The whole thing is wood and I have an idea how I want to install the passive intake and the carbon filter and exhaust. My question is how do I put a whole in the wood? I used a skill saw to cut the door and that obviously isnt going to work to put the whole in. I am going to need 2 4" holes on one side at least that I will be mounting PVC elbows to. Secondly I will be mounting my 120mm PC fan for carbon filter and exhaust. So I will need to be able to cut the whole and mount the fan. Any suggestions are certainly welcome.

Thanks

You can use foam weatherstripping for the front of the door. For the holes your options are a drill bit hole saw, a jigsaw (orbital?) or an adjustable circle cutter for a drill. I used a General Tools circle cutter with a cordless drill. Check my profile I started a thread on cutting holes because I was in the same boat you were.

MrDank007 said:

You can use foam weatherstripping for the front of the door. For the holes your options are a drill bit hole saw, a jigsaw (orbital?) or an adjustable circle cutter for a drill. I used a General Tools circle cutter with a cordless drill. Check my profile I started a thread on cutting holes because I was in the same boat you were.

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Thanks. Your thread helped me get an idea. I can do the holes now. I am going to grab some weather stripping today and see how it goes.

No prob. Let us know what you used and how it worked!

The weather sttripping was a PITA! My door is warped so it made it very difficult. Still not sure its 100% but we'll see soon enough.

yeah man a hole saw bit for your holes. practice on something b4 you try on your box cause they can be tricky to get at first (i had teeth marks alllll over my pvc from initial slippage)

I bought the hh-300 hole saw from http://www.holepro.com/drillpress.html and like it. Isn't good for tight spaces.

happy building

Yeah the weatherstripping can be a nuisance. My cab has 4 doors on adjustable hinges. I played with different widths and types of weatherstripping to get it right and finally did. Then after opening the door half a dozen times it was screwed up again. Depending on the size of your cab, you could just nail a canvas blanket up and let that be the door before your real door...Good luck and I would second Jordy Villain to try a practice piece first and add to wear goggles when doing the holes

MrDank007 said:

Yeah the weatherstripping can be a nuisance. My cab has 4 doors on adjustable hinges. I played with different widths and types of weatherstripping to get it right and finally did. Then after opening the door half a dozen times it was screwed up again. Depending on the size of your cab, you could just nail a canvas blanket up and let that be the door before your real door...Good luck and I would second Jordy Villain to try a practice piece first and add to wear goggles when doing the holes

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After seeing a video online a few days ago I decided on making a door before the door using the reflective materials I am lining the inside of the cab with.