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Ladder Core Exterior Door2/2
I am getting ready to build a ladder-core entry door. I plan to use stave-core material for the parts and 1/8 veneer for the faces for a total thickness of 1.75. The door itself is a double, with each door at 30" x 80".
The advice I've read here points to filling the gaps in the ladder core with rigid foam. My question is this: can I simply press the 1/8 veneer (with all grain vertical) directly over this ladder/foam construction? Or do I need a cross-grain layer between the frame and the face veneer?
Secondarily, will I simply glue the foam surface and the ladder frame surface with the same adhesive under the veneer face?
I do not know anything about gluing to foam, but I would not count on it over time.
I do know that 1/8" skins will not work well on a what I term a ladder core door. The ladder core is merely a rigid frame to hold 1/2" or thicker ship lap or T&G boards in place, usually on both sides of the ladder core. The edges of the 1/8" will not stay tight or in the same plane - probably why you want to count on the glue to foam solution.
The 1/8" parts will mandate something like a flush door, with particle board or similar core. Must be stable - no movement. So, mixing up stave core parts and what is essentially veneer is not a good idea, if I understand you correctly.
If you want a plank look, use thicker facing boards, with some lap in the joints. If you want a frame and panel door, just use your thick veneer to face the stave cores. If you want a flush door, then use a solid stable core and press the veneer in place. At 1/8" you will have to edge glue the seams.