I am building an addition to a home with many high end features; one of which is a 36″x96″ paint grade 4-panel interior passage door in a curved wall with a 7’9″ radius. The door will open into the room on the convex side of the wall. The custom door shop I’m ordering from has expressed concerns about their ability to make a stable door of this design. I may have to make it myself.
I’ve built standard frame and raised panel doors before but never a radiused one.
I’ve considered building up layers on a form with curved cauls; or brick-laying blocks and surfacing the blank with a router running on a track.
Trial and error on something this large would be extremely time-consuming unless I got it right the first time.
Any suggestions and stories of similar problems solved, materials used would be appreciated.
Thanks, Steve Doane