A client wants me to build a door she has designed. It is 42" x 95" with 13 approximately 7" x 42" x 1 3/4" horizontal slats(?), v-grooved. I know I can't just glue up such a wide door. How can I build her what she wants? Also, she wants the door wire-brushed to give it a distressed look, which I think means I don't have the option of veneer, which also is not available here where I work in Mexico. My plan is to use solid 8/4 alder. Any ideas would be greatly appreciated.
(Architectural Woodworking Forum)
From contributor J:
One method could be to use a core of something stable like MDF or similar, and then use thinner solid slats, maybe 1/8" or less - just thick enough to allow you to do your v-groove and wire brushing.
I think using all solid wood in the method you describe will almost certainly be problematic. But your climate may help. Up here in the Northeast, the seasonal movement would be pretty bad. I don't know how much your temps and humidity change through the seasons, but if they stay the same year round, you might be able to pull it off.