Darryl Keil Last Activity 2025-05-12 11:03 AM
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BigRob777

Posts: 142

Joined: 2008-05-26
Location: Newark, DE

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Subject : Solid Core Door Construction?
Posted : 2008-11-06 11:10 AM
Post #35031
I have to replace a door for my parents and need to know if I can cut down a home depot 36" wide door to 34" wide. Does anyone know how wide the rails and stiles are on their solid core doors? I'm looking at the plain flat ones, so I can veneer it with curly anigre'. I don't want to leave the stile too thin. I've never seen a door like theirs. It was hollow-core and 81-1/4" high by 34" wide. It is a mobile home, which probably explains the oddity.

Has anyone disected a door like this? I could go to Lowe's, but it's farther away.

Thank you,
Rob


 
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craig tufankjian

Posts: 308

Joined: 2004-02-01
Location: syracuse ny 13208

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Subject : RE: Solid Core Door Construction?
Posted : 2008-11-06 11:23 AM
Post #35032 - In reply to #35031
hi rob.
the rails are about an 1 1/4 wide. what i usually do is trim the door to the final size the take a rabbit bit and route out the particle board core to a depth of 3/4 inches. then use maple or birch to infill the rabbit.

you can order a 34 inch door from home depot. lead time is about a week. if you do go that route order a door that has a rotary cut door skin face on it. that way you wont need to two ply your faces.

you will also have to make sure that all your edges on the door are sharp. all doors come with a 1/16 th radius on the edges, which in the veneering process will not adhere.


 
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BigRob777

Posts: 142

Joined: 2008-05-26
Location: Newark, DE

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Subject : RE: Solid Core Door Construction?
Posted : 2008-11-06 4:16 PM
Post #35033 - In reply to #35032
Craig,
Awesome info, thanks. I forget, can 1/4 underlayment work for the top caul?
Thanks,
Rob


 
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craig tufankjian

Posts: 308

Joined: 2004-02-01
Location: syracuse ny 13208

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Subject : RE: Solid Core Door Construction?
Posted : 2008-11-06 5:11 PM
Post #35034 - In reply to #35033
Rob,

The best caul material i've found is marlite. it's masonite actually but covered on one side with white phenolic. I used to get it at home depot for about 11.00 per sheet but I found another source for 8.00 per sheet.

Can be used for both flat and radius work. radius to a degree of course. it's just shy of 1/4 inch , and any glue which gets on the face easily flakes right off. you can find it in the panel products isle at home depot. There are generally two kinds, one is flat white plain, and the other is embossed to look like ceramic tile 4x8 sheets. (you dont want that)

Best caul material you can use in a vacuum press in my opinion.

What else i've found is "less is more" in reference to a caul. I used to use 3/4 melamine. not good.....
the only time thicker is better is on the caul used in the bag. )the one with the groves routed in it that you hook the vacuum press up to)


 
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BigRob777

Posts: 142

Joined: 2008-05-26
Location: Newark, DE

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Subject : RE: Solid Core Door Construction?
Posted : 2008-11-06 5:45 PM
Post #35035 - In reply to #35034
Craig,
Thank you. That's valuable info for me. If I have to, then I would guess that I could use the 1/4" stuff (in a pinch). Would I need a platen, if I'm doing a door, top side only (then the other side)? I'm not in the mood to build a door sized platen right now. They're really heavy.
Rob


 
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Don Stephan

Posts: 825

Joined: 2003-07-18
Location: Cincinnati, Ohio

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Subject : RE: Solid Core Door Construction?
Posted : 2008-11-06 8:05 PM
Post #35036 - In reply to #35035
Rob:
A channel is needed for the air in the bag to reach the vacuum hose. This, and providing a flat surface, are the primary features of the grooved caul. If not using a grooved caul, you'll need enough Evacunet to allow all the air to reach the hose. By the way, I tried gutter cover in a pinch. It looks similar to Evacunet but is a VERY poor substitute. A grooved caul would be much easier to use in my experience.


 
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BigRob777

Posts: 142

Joined: 2008-05-26
Location: Newark, DE

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Subject : RE: Solid Core Door Construction?
Posted : 2008-11-06 8:59 PM
Post #35037 - In reply to #35036
Yeah, I tried the gutter guard netting too. It didn't work. I do have a large roll of the right stuff, that I would put under the door, which would lay flat on my work bench. I might as well get the platen built. It's rough on my back cutting those grooves, but it'll be better than trying to clear off my work bench every time I want to veneer something.

I made the mistake of cutting up my platen, into quarters and then found out that wouldn't work. Now I have two nice pieces for most of my work, that's 2' X 4' melamine rounded up nicely and grooved and the same size for caul, for the top. I'm guessing that a 3/4" X 2' X 4' top caul would work, as it's much smaller than a door. If not, I'll use it for a table extender, for my band saw.
Rob


 
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BigRob777

Posts: 142

Joined: 2008-05-26
Location: Newark, DE

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Subject : RE: Solid Core Door Construction?
Posted : 2008-11-23 5:18 PM
Post #35080 - In reply to #35037
Craig,
I bought a piece of that material and it looks awesome for the low price. My next question is this: How do I treat the edges, so that glue doesn't stick to them?
Thanks,
Rob


 
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craig tufankjian

Posts: 308

Joined: 2004-02-01
Location: syracuse ny 13208

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Subject : RE: Solid Core Door Construction?
Posted : 2008-11-23 5:36 PM
Post #35081 - In reply to #35080
By "stuff" do you mean the white marlite panel product from home depot? to use as a top caul?

If so I wouldn't worry about the edge's. by edges you mean after you cut to size , those edges? you should hit the edges with 120 sand paper to ease them a bit and take away any sharp edges.

if i mis-understood the question please define what edges you mean.

craig


 
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BigRob777

Posts: 142

Joined: 2008-05-26
Location: Newark, DE

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Subject : RE: Solid Core Door Construction?
Posted : 2008-11-23 9:38 PM
Post #35085 - In reply to #35081
Craig,
Nope, you understood me. I just couldn't pull up the name on my screen. What an awesome product for such a cheap price.
Thank you,
Rob


 
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BigRob777

Posts: 142

Joined: 2008-05-26
Location: Newark, DE

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Subject : RE: Solid Core Door Construction?
Posted : 2008-11-23 10:23 PM
Post #35086 - In reply to #35085
BTW, my folks opted for a steel door, so no laminating was needed.
Rob
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