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I have been asked to bid an entry door that is 4'-6" x 9'. It is a slab door with 1/8" veneer on both faces. My question is what type/kind of substrate should be used on a door with these specs.
Id say block core
we built a 4x9 slab door with pivot hinge and a 2x9 fixed panel next to it. we are in Ohio so concern was for some insulation so we built it 1-3/4" door with foam core and 1/4" exterior grade plywood skin bonded to the foam core. The frame of the door was 1-3/4" by 2" Sapele and rabbeted to accept the plywood. The skin was horizontal slip matched ribbon stripe Sapele, (I think book match would have been better) then stained a dark color. This was three years ago and only issue is that it faces east and the morning sun has damaged the veneer. Client was aware it needed annual inspection and maintenance but did nothing. The door is still dead flat and the only damage is on the lower part of the doors exterior. I came on this forum today to post a question about better exterior materials and finish materials for repairing this project. We are considering using Total Boat penetrating epoxy followed by Epifanes varnish or using Chemcraft D-Dur PU clear top coat. Hope my comments are helpful and any suggestions on improvements are welcome.
We also would use Blockboard for a door like this. We recently made some 6' x 7' doors with a Blockboard core and 1/8" shop made veneers.
You can frame the Blockboard with solid wood matching the veneer so that it doesn't need to be edgebanded after being cut to size. That could work well for you here to build out a few inches of a matching solid wood to get to the size door you need (meaning, get a 4' wide Blockboard and add 3" of solid wood to either side to get to your 4' 6" width).