I have the framing and hardware installed for a (nominal) 48” wide pocket door off my front foyer. Well, it needs a door and I’ve decided to have a go at building one.
The other interior doors in my house are the common hollow core, wood grained, 6 panel doors common at the home improvement stores. They are painted white. This door will be just a few feet from the front door, which is a wood grained fiber glass door that looks like a stained & finished wood door (if you don’t look too close). It is also panel style. So its clear that I want a panel style door, but it could be either stained & finished or painted gloss white depending on how it turns out. I plan on matching the sizes of the rails, stiles, and panels that are on the other interior doors, so I am planning on 9 or 12 panels in this door.
Because of the large door width I installed the split studs to handle a 1-3/4” thick door.
I’ve looked at a number of postings on doors here on LJ and also on another woodworking site. It is probably overkill, but I am planning on following more-or-less the construction method described by a1jim here. Because this is a relatively big piece and this process uses a number of techniques that I’ve never done before I’m going to take some advice I got on my earlier post and make the first one out of construction grade 2x’s.
The first part of the process is to build up blanks for the rails and stiles. Jim describes a 1-1/4 core that sounds to me like butcher block, that will be covered with 1/4” skins. I do have a couple of questions I hope someone can help me with:
- Should I plan on using a vacuum bag when I go to gluing on the 1/4” skins?
- Does finger jointing significantly improve the stability of the blanks? It’s going to feel silly chopping up long stock into short pieces just to assemble them back into long pieces again, but if I do that I suppose that the pieces should be mixed up before assembly.
- When its time to make the real door out of hardwood, are there any ways to save money on the material used in the core? Can I use a less expensive species, or is there someplace that will sell short scraps at a discount?
This is looking like it’s going to be quite an educational experience. Ouch.
-- Greg D.