Composite door

In order to improve dimensional stability; the door was comprised a composite of 9mm Birch ply, and selected solid Maple slats each side; dowelled-through.


The dowelling lines were first plotted, then a drilling template aligned to maintain consistent hole distribution.

40mm solid processed Maple was ripped into around 45 slats, sanded and edged.

A frame fixed over the workbench allowed each slat to be independently wedged.


Half-sized dowels were produced to suit the sheet thickness, then skimmed down to size on the reverse.

With both sides of the sheet slatted, the top and bottom were rebated to sit in the outer frame (rails).

A small dowelling template was used in jointing the solid outer frame.

Channels were also made for the door hanging gear, using a sled on the table saw.