Flat slab doors

[dng]

Hi I was wondering if anyone new how to make some flat slab doors, for a pocket door system.  Is it as simple as gluing some pieces of ply together?, or would I need to use rail and stile?  The reason I wanted to make them is because they need to be 8' x 3' x 1-3/4" and then have a custom design routed in.  Any advice would be much appreciated.

Thanks

Darren

 

[Frank-Jan]

Over here they sell ply that's 40 mm thick for that purpose. (40 mm is the most common door thickness here). I made a bunch of interior doors for a client that wanted a design of shallow vertical lines routed into them, and also an exterior door with the same design, but for that I used a special version with two aluminum layers in the ply to prevent warping.

 

[LBIsackson]

Is weight an issue? If not buy 3'0"x8'0" solid core slab ...you can't make them cheaper... Just use a heavy duty tandem track
If you want to make a hollow core door ... Remember to support and block the inside otherwise you'll have a lot of warping and use straight stock for your rail and stile.. Just think of it as building a torsion box... Seriously it is cheaper buy it than spending a day putting it together ... Unless someone is paying you do it .. Or there is some design feature that can only be had this way....