OK, I found a lot of info on making interior doors, and a lot of it is contradictory as well, which just means lots of opinions abound. (And that’s a good thing!)
I’m a hobbyist, so time is not an issue. It ‘seams’ that a good way to insure doors stay true is to make an interior (and possibly exterior door as well) by laminating the rails and stiles, and then cap and veneer them. What I had in mind was, for the rails and stiles, is to take Poplar boards and rip them, alternate the rip pieces over and re glue them. Once set, then place 1/8 or 1/4 veneer on the faces, as well as 1 inch on the outside and inside edge. I’d suspect that should make for a very stable door.
Opinions? Is this a good way, or is there a better way? And if so, what is the best way to laminate in this case – after the rips alternate the orientation of every other cut by 180, but leaving the ends on the same side, or should the ends be alternated as well?
Thanks,
Fred
Replies
Hi Fred,
You are describing stave core construction, and that is the way to go.
You can purchase stave core materials from several mills.
These parts are then edged and veneered then shaped into the various stiles and rails.
If you don't mind making the stave core material, then by all means have at it.
It would probably end up lesss expensive to just buy the ready made pieces and procede from there.
J.P.
I read your post and I got to thinking that with the interior of homes being so climate controlled nowadays, is all that work necessary?
Couldn't you just make the door out of the solid wood and veneer that? Unless you want to do all the extra steps to be extra thorough. (I do that sometimes too.)
The reason I ask is that I have a few interior doors to build also, but I was just going to use solid boards. (The doors will be painted - maybe that makes a differnece.)
Thanks.
HB
I had this discussion with JP many months ago and after his comments along with some research on the woodweb, I opted to go with his suggestions. It is a lot more work, but I decided it was worth it eventhough given the climate i live in, it is very unlikely going to ever be a problem. I couldnt find any quarter sawn lumber that was reasonably priced, so I used a glulam core and a veneer slightly thicker than what some suggested (see pic). I also found MDF and engineered lumber was a popular core material. I am thinking about building one of my future doors using a rigid insulation core but that will take a little more planning to coorinate all the joint locations. If they can build a wall structure (SIP) with a structural insulation core, I figure I can build an interior door too.
Best of luck
Thank all for the responses, looks like I'm on the right track. Yes, it's a bit more work, but knowing Murphy's law, if I don't do it, I'll get bit. Besides, the experience will be fun!Thanks,
Fred
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