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dadiOH[_3_]

wrote:
Just finished building a new shop. 24X24 One wall will have a large
section of shop built cabinets. I'd like to put doors on the cabinets
to keep the dust out of my stuff (well at least try). I want fast
cheap and dimensionally stable. I could cut up a bunch of 3/4 MDF for
the doors but that stuff is heavy and the hinges may rip out with
shop use. I could make real rail and stile doors with a ply panel but
that is a lot of work for a shop door. Plywood warps unless you use
the expensive baltic birch stuff.

Then I had an idea. I'd like your comments. What if I took a sheet of
1/4 luan and laid it on the concrete floor. Using liquid nails I
glued a series of 1x4 clear pine in the shape of the desired door
sizes. Then I glue another sheet of luan to the top. Compress the
whole thing with concrete blocks. After a couple of days, cut out the
doors by ripping them such that each door has 1/2 the width of the
1x4. I'd end up with a light, strong and dimensionally stable, door.
A 4x8 sheet of doors at a time. Would they be as good as I think?

You are making hollow doors, should be fine. The only problem you may
encounter is with hinges and that depends on the type. Your doors are going
to wind up about 1 1/4 thick so you need hinges for that.

When I make hollow doors (or panels) I rip the rails/stiles a 2x4 so that
they are 1/2 or 5/8" thick. I butt glue the rails to the stiles and run 2 -
1/4" dowels through each corner of the stile into the rails.

For skins, I use luaun door skins which are 1/8" thick. They are glued on
with yellow glue. Concrete blocks might work, don't know as I use home made
clamps along each edge which is where you want the pressure, not in the
middle. The clamps are rings about 3/4" wide cut off a 2" PVC pipe and then
split on one side. One doesn't put on much pressure but when thay are
spaced 6" or so apart it is plenty.

--

dadiOH
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