Replies

1. 
   MBerger | Jan 23, 2007 06:06pm | #1

   Hi Jackmack,

   I hate to be the bearer of bad news, but I think your only option here is to make a new door. Even if you are able to coax it back to flat it will likely move again.

   You should be able to salvage the panel so it's just a matter of milling up new stiles and rails and reassembling them.

   I have a question for you: Did you joint and plane the lumber for the stiles and rails, or did you use pre-milled lumber? If you jointed and planed, then I suspect the wood wasn't completely dry when you milled it. If you used pre-milled lumber, than most likely you started out with a warp and it carried over to the final assembly. Another cause for the warp could have been due to the joinery; possibly one of the corners didn't go together square.

   If you're dead set against building a new door you can plane the door flat by wedging the high corners and removing the high points with a hand plane. But that is going to cause a number of problems, including creating a thinner door than the rest, and creating an inconsistent thickness.

   Regards,
   Matt Berger
   Fine Woodworking

1. 
   jackmack | Jan 25, 2007 04:47am | #2

   thanks for the info. Thats what I did, salvaged the panel and made new stiles and rails. It was off the shelf poplar from a local lumber yard. thanks again for your advice. jackmack

   Edited 1/24/2007 8:49 pm ET by jackmack

1. 
   MBerger | Jan 25, 2007 03:40pm | #3

   Glad to hear it worked out. Do be leary of using premilled lumber without jointing and planing. Unless the mill did a really good job, most likely this lumber will not be perfectly flat or square.