There may be a time when cost or necessity dictates that it is more sensible to use what we call a "Door Blank". Clicking on the images below will take you to the correct page on our website.
A door blank is what could best be described as a blockboard construction which can be seen in the images. This is when narrow strips of timber are laminated (glued) together and are then overveneered with plywood faces. They are available in numerous sizes but generally speaking are most commonly cut down from 2135x915mm or 2440x1220mm.
The fire door blanks are available in 1/2 hour fire rating at 45mm thick and also in a 1 hour fire rating at 54mm thick. If you have a really unusual size they are a very reasonable choice but you must be prepared to cut them down and then go to the trouble of putting timber edges back on to them, if the door is being used in an external location then you must also add an edge to the the very top of the door otherwise the veneered faces will almost certainly peel away from the timber core.
I am of the opinion that it would be best to leave this type of work to a Joiner/Carpenter, unless you are a confident DIY'r.
The above images show a door blank being cut down in our workshop, for a customer in the South of England. We tend to use 12 to 15mm thick hardwood edges which we glue and also nail in position before finishing the faces with a sander.
Please make sure that this type of door is primed, undercoated and painted on all surfaces and edges if being fitted outside. If you intend to stain the door-blank make sure you give it plenty of coats. Again, don't miss the edges.....any of them!
Any questions, email firstname.lastname@example.org
Info supplied by www.DirectDoors.com