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I need to build a shaker stile door approximately 70" tall and 24" wide. The client wants a mirror in place of the standard flat panel. My thought was to use 1 1 /4" rails and stiles with a 3/4 rabbet and laminate the mirror to a 1/2" piece of plywood then insert it from the back. Does anyone have any experience with this application or any suggestions? I'm worried about the weight of the door and flex as the door is opened and closed.
Is this a walk thru door or a cabinet door?
It is a large cabinet door.
In that case I'd make it as a normal glass rebate door using 2 1/4 style/rails, cope and stick joint with 3/8" x 2" dowels in the corners. after finish I'd use two sided foam glass tape and stick the glass by where it does provide some strength holding the long styles in position. if you are using euro hinges check the weight as to how many you will need. my guess is four will do it.
I have done doors similar to what you are considering. I did one door which was 80" high x 24" and we made it 1 3/8" thick just as we would make an interior door. We put a 1/2" plywood panel into the dado and we used a mortise and tenor construction and then glued on the mirror.
If you do glue on the mirror, be sure you spray on a protective coating before you apply the glue and use glue designed for that purpose or the mirror will develop cracks.
Hinging might be an issue. So you will need to think this one through. For the door above, we were making a mirrored door in a closet which was designed to hide a cabinet which hide a safe. For this door, I use three Soss hinges. If you do not have a CNC, something like this is really difficult.
I also did some tall cabinet doors, not this tall or this wide, where we used 3/4" stiles and rails. There, I put 3/16" mirror into a frame that had a dado so that it could be dropped in like you are proposing. We used silicone to secure the mirror. Then we mounted 1/8" plywood onto the back of the door. We screwed the plywood on to the frame and finished the plywood. We put cardboard in between the glass and the 1/8" plywood. The plywood was larger than the mirror opening. We had to make cutouts for the hinges. For these doors which were about 18" x 60", we used four cabinets hinges per door.
I hope this helps.
Bruce and Paul, thank you for the help.