Assembly

The middle layer of the door is glued and screwed to one of the exterior layers, and the final layer is then glued to the middle. Now the assembly is clamped to the flat work bench to hold all of the layers together under pressure. This should close any space between the layers. Excess glue is wiped off and the door is left to cure over night. The next day, the door is ready for fitting into the jamb, staining and finishing, adding glass and hardware, and finally hanging.

Note: A door constructed in this fashion is approximately two and one quarter inches thick, thus requiring a custom jamb (easily constructed from the same 1x6 lumber). Also, due to the weight of the door, consider using four hinges, instead of the usual three.