Questions about pantry door

rnt80

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Joined
Mar 30, 2008
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I have to build a 30" x 96" pantry door for a previous customer that needs to match their existing kitchen cabinets.  In order for everything to tie together he doesn't want a lock set but rather a ball catch at the top of the door.  Additionally, he wants to use one of the large cabinet pulls that match his other hardware instead of a traditional door knob.  I looked to outsource the door but that proved too costly so it looks like I'll be building it myself.  It's just a traditional 6 panel door but the customer doesn't necessarily want raised panels on the back (making it more cost effective) since no one will ever see the back of the door.  That got me thinking about possible solutions.  I could just do flat panels but I was also wondering about using plywood.  Does anyone see any potential issues arising if I make the front of the door in a traditional manner with a little less than 3/4" stock (since the door needs to be 1 3/8" thick) and then essentially back it with some 3/4" ply?  I know that the edges need to be solid stock for aesthetic reasons and so that they can accept the hinges.
 
The only issue I can forsee is the probabilty of the door staying flat. Plywood rarely stays dead flat in sheet form unless firmly secured to a substrate that won't move, I fear that the 3/4" face panel will not be enough to do so.

Could you make it more traditionally, solid stiles and rails with panels that are moulded only on the outer face, these could be easily set into a groove or rebate and the rails joined to the stiles with good old Dominoes. I suspect it would be a quicker job than the plywood faced and lipped idea.
Ball catch at top only  might be better replaced with 2 or 3 good mag catches down the edge.

Rob.

PS. Check out this old thread of mine 330 Domino's
 
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