Need to make a door

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KLF

Frame waxer
SILVER Star
Joined
Apr 5, 2003
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10,207
Location
Southern NH
Looking for tips from the woodworkers in the group. Slowly renovating our camp which is really just a very old (mid-50's) house trailer sitting on a very small lake lot. There's a sliding pocket door that separates the kitchen from the bathroom, the original one has a bad water stain and it's delaminating, not salvageble. I want to make another one, the door will be only 23-1/2" wide, 76" tall. Thinking of making a simple frame out of 3/4" lumber, just a pair of stiles with 4 rails, then laminate a sheet of 5mm thick maple-veneer plywood on each side, one 4x8 sheet will do both sides. I have a nice Kreg jig setup to make the frame. Wondering what species I should use? Will pine be OK, say 1x3's? Or will pine warp, maybe I should use poplar?

How should I attach the plywood? Just glue? I have 15 ga and 18 ga nailers, but don't want the heads to show. This will be stained, not painted.

What should I do about the only edge that shows? The door will be about 1-1/8" thick when I'm done, so I can't just use that iron-on veneer banding.
 
I would do a 3/4" plywood (a nice cabinet grade that has a better tendency to stay straight) and Kreg and dowel it together. Then I would cut a nice veneer ply, and contact adhesive it to each side (a can or two of the 3M heavy duty stuff would work)...then trim it flush with a router, put a slight bevel on it, lightly sand and you're ready for finish.

Your biggest challenge these days is find a friggin piece of wood worth a s*** that's straight.
 

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