I want to replace my current double exterior door. Well it is an exterior
door on both sides, the outside is facing the street, and the inside is
facing the courtyard. So it's not an entry door to a building structure.
The existing door is a hollow wood door and the bottom is rotted from being
too low touching the deck where there is moisture, and the hinges are
I would like to replace it with a solid wood door, and I don't want anything
fancy just two slabs of 3/4" wood 30" W x 78-1/2" H x 3/4" D and I would
like to have a normal cylinder lock, a dead bolt, and top/bottom flush bolts
on one door.
It seems the big box stores only sell doors with fany panels and cravings
which I don't care for. I called two local lumber yards and they don't do
Anyone know of a good source that would do custom sized plain jane solid
wood flat door with custom routing of hinges, locks and flush bolts?
Thanks in advance,
Just about any carpentry shop. However...
1. You won't get a "normal cylinder lock" into a 3/4" slab. Nor a normal
2. A solid, glued up 3/4" door is going to warp like crazy.
What you need are doors at least 1 1/2" thick made with rails and stiles.
If you want them to last, use rails & stiles at least 6" wide - wider is
better - that are morticed together. A center rail too. To fill in the
empty space you could use either a 3/4" floating panel or apply boards of
whatever thickness to one side but they'd need some space between them.
If you want an authentic look for your Spanish style manse, have the doors
made of "cedro" (Spanish cedar) and oil or varnish them. Go find a
Mexican/Cuban carpenter in Hialeah, he'll fix you up. The bolts normally
used on doors like you want are called "cane bolts".
Shouldn't be hard to find solid-core slab door. Whether you can find
one rated for exterior use or not would be the hard part, probably. I
have several I've bought from used/recycle/unclaimed freight types of
places that I use for bench tops, etc. They're all veneered, of course,
not solid lumber but they are solid, not hollow.
It shouldn't be at all hard to find a 2-panel exterior door at the same
places which would be my suggestion if looking for the inexpensive solution.
Otherwise, I'd echo DadiOH's suggestion on material. However, I'd think
in your area the other sources would have quite a lot of cypress and
other suitable materials available as well.
Given your problem I wouldn't hesitate to order a fiberglass door from
one of the companies like ThermaTru. Not cheap, but they have a huge
selection of styles, even some rather plain offerings. Corrosion
resistant hardware should be no problem. www.thermatru.com. Good
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