Thread Tools Display Modes
Old 06-12-2013, 12:31 PM   #1
Senior Member
Baggiolini's Avatar
City: Monterey, CA
Country: USA
Vessel Name: Mahalo
Vessel Model: Defever 44
Join Date: Jun 2011
Posts: 399
Replacement doors

Mahalo's entry doors are dead and due to the way they were manufactured, it looks like a hell of a job to repair so I am considering replacing them. Anyone been down this road before?

I'm thinking a solid door made of mahogany or teak if I can find it.

Attached Thumbnails
Click image for larger version

Name:	photo.jpg
Views:	86
Size:	86.9 KB
ID:	20413  

Baggiolini is offline   Reply With Quote
Old 06-12-2013, 01:42 PM   #2
FF's Avatar
Join Date: Oct 2007
Posts: 17,223
Plywood is usually the easiest to work with with a veneer of whatever you like glued outside.

We will be making a set of dutch doors so we can handle bigger slop , and ventilate as FL requires.

FF is offline   Reply With Quote
Old 06-12-2013, 06:30 PM   #3
Brooksie's Avatar
City: Cape Cod, MA
Country: USA
Vessel Name: Island Seeker
Vessel Model: Willard 36 Sedan
Join Date: Oct 2007
Posts: 975
A sheet of 3/4" teak veneer marine plywood is about $180 but I bet your doors are more than 2' wide so you need 2 sheets. Making paneled doors from solid lumber will look much better for sure but it is a job for an experienced cabinetmaker and requires specialized tools & equipment. Re-veneering the existing doors is also an option if the cores are still good and they could be done in teak. They won't look like paneled doors when you are done but they don't now anyway and this would be the cheapest avenue by far. They look like they have an aluminum channel around them
this could be removed, the veneer planed off and replaced
Attached Thumbnails
Click image for larger version

Name:	027.jpg
Views:	63
Size:	93.5 KB
ID:	20438  
Brooksie is offline   Reply With Quote
Old 06-13-2013, 10:54 AM   #4
Scary's Avatar
City: Walnut Grove Ca
Country: USA
Vessel Name: Cary'D Away
Vessel Model: Hatteras 48 LRC
Join Date: Apr 2012
Posts: 887
Wood Doors

Style and rail doors would be the best solution. Teak or Mahogany wood be the best choice. Solid , as in a slab the size of a door, is difficult to keep from swelling and warping. Style and rail design allows for some swelling of the panels without distortion or warping.
Most cabinet shops are set up to build cabinet doors. There are also custom door builders as well.
You could glue up plywood panels with epoxy, hope they remain stable and the thin veneers don't sand though. It would be best to glue the panels in a press of some kind. The plywood panels are not usually flat enough to glue up without pressure. A flat surface and a stack of 15 sheets or so of 3/4 mdf has worked for me in the past as a poor mans press.
I have built doors using a router and style and rail bits with success, however you need to dowel, or use floating tendons, to tie the rails to the styles.
Another option wood be to just build your rails s4s and use a round over bit to profile the inner edges of the frame and dado the groove for the panel with a router. The panel could be 1/2" teak plywood single or doubled up. Again you would need to use dowels or tendons to tie the frame together. The panels need to float in the frame to allow for movement between the panels and frame.
One of the challenges in building doors is keeping them perfectly flat. all of the solid wood should be machined from rough lumber as surfaced lumber is seldom flat enough to work with. If you have some basic wood working skills and tools, building doors is not rocket science.
Scary is offline   Reply With Quote

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off

All times are GMT -5. The time now is 04:30 PM.

Powered by vBulletin® Version 3.8.8 Beta 4
Copyright ©2000 - 2018, vBulletin Solutions, Inc.
Search Engine Optimization by vBSEO 3.6.0
Copyright 2006 - 2012