After a few days off to battle the flu, I have started construction on the entry door! I would like to address the method of construction and materials. In the following pictures, you will see that I am using stave core construction for the interior core of the door. This method makes use of smaller blocks of wood joined together with glue, to form one large panel. The biggest reason for using this method is to keep the door from warping. In essence, if one piece of wood decided to warp, it would have to drag all the surrounding pieces with it. Done properly, this door should not have a warping issue over its lifetime. For more information on stave core construction, please follow this link. Why white oak? Because the pores in white oak are more dense than red oak. Also, if you look at a cross section of red oak, you will see that there is moisture in the pores. This makes white oak a more sound structural choice. Follow this link for more info. Ive used Titebond III for the glue. This particular glue is waterproof - ideal for an exterior door. This core will dry for the entire weekend before I pattern it out. The customer has asked for a flush door with no panels, so I will eventually be applying 2 layers of 1/4" oak over both faces.
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