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Making front door

Posted by oldscout (My Page) on
Sun, Sep 16, 07 at 12:37

I want to make a new craftsman front door for my home. When I went to one of the larger hardwood dealers in the SF bay area and looked for 8/4 oak for it I looked through a lot of wood and could not find stock long enough or wide enough that was even close to straight and true. I have a jonter and planer so glue ups and milling are not a problem. Has anybody made a door by laminating 4/4 stock up to the 1 3/4 thickness needed for and exterior door?

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RE: Making front door

Very inadvisable. The stresses from laminating two boards and exposing them to extremes of heat and climate lead to great warping possibilities. The best old time thick doors were a poplar or white pine core with 1/8" hardwood veneer. In your case, you could resaw oak into 1/4" stock, laminate it to the core, then plane down to finished thickness. Unless your jambs are already determined, you could do a 2.25" door, which is a very substantial thickness.
The softwood core winds up much lighter than solid hardwood, which means it's easier on the hinges in the long run.

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