We now have an 'odd ball' sliding patio door due to house settling (expanding?? ).
I'm an experienced woodworker and was wondering why not make my own sliding door with a customized height? I don't see anything particularly difficult about it. It wouldn't be very adjustable obviously. But why not? I can route a screen channels, make mortise and tenon joints, and plane the wood so it fits within the existing opening (thickness). Has anyone ever done this? pitfalls ? (I don't see any). I''d probably make it out of white oak or cedar for the weather. Opinions?

 

Almost nobody does it because of the machinery, labor and skill required to build a sliding door & frame. Certainly it can be done but unless you are an experienced woodworker with a well equipped shop it's really not an option. Even if you do have the wood, skill and tools it will be a project you have to "want" to do because if you look at your labor it's still probably cheaper to buy a factory made one.

If your house is settling and moving I would look into how log homes are built. Most include an oversized rough opening and the door or window is held in place with fasteners in slots so the building can move somewhat without affecting the door. Then if it does affect the door you pop off the trim molding and can do some simple shimming and adjusting to get things square and working again.