Free USA Shipping on Store Items

Flat rate $110 to Canada. Contact us for AK & HI

Call us at

(208) 412-7823

You are here

Flush Plank Doors

A flush door is built with one flat surface on both sides rather than a stile and rail architectural door that has vertical and horizontal frame members that have floating panels inside.  Our flush plank doors can be built with a number of different techniques that you should discuss with us concerning price, look and performance.  A number of manufactures will simply edge glue together boards.  This is fine if one is not worried about stability, movement or the door staying flat.  Our lowest cost option would be to do something similar but actually face glue two halves together of solid wood to make a lamination.  This will help for rigidity, but we would not recommend this door for an application such as an entry door or anyplace that movement was a concern.  It works well for a lower price point sliding door application.

A more stable option is to build with an engineered stave core frame concealed under wide planks laminated to the surface. The exterior of the door looks like solid wood boards but they are actually 1/4" thick veneers laid up over a more stable core.  The majority of the inside of the door can be made with a laminated closed cell foam product which lightens the door and adds superior insulation properties. On an exterior door we can achieve an R5 rating or better (depending on how thick you will let us build your door) which meets Energy Star requirements. An alternative to the foam product that we use is lumber core veneer sheet laid in a series of layers and laminations. Either way, our flush plank doors have solid wood edges and are engineered to stay flat.

You can choose any level of texture and wood types to go on the surfaces. Additional decoration can be added such as Z or X braces made from boards and bolted on or metal hardware looks is a great addition, too.

The main two reasons to go with our flush plank doors would be the energy efficiency in an exterior door or the clean and simple look.

  • horizontal plank entry door
    1/16

    horizontal plank entry door

  • Pantry full rough texture brown
    2/16

    Pantry full rough texture brown

  • exterior plank door with sidelites
    3/16

    exterior plank door with sidelites

  • unfinished flush plank door prepared to receive window
    4/16

    unfinished flush plank door prepared to receive window

  • random width softwoods
    5/16

    random width softwoods

  • unfinished oak planks
    6/16

    unfinished oak planks

  • installation of double barnwood flush plank doors
    7/16

    installation of double barnwood flush plank doors

  • painted red reclaimed plank door
    8/16

    painted red reclaimed plank door

  • engineered with foam core full rough grey exterior
    9/16

    engineered with foam core full rough grey exterior

  • full weathered grey interior solid wood door consistent width planks
    10/16

    full weathered grey interior solid wood door consistent width planks

  • mixed colors full rough texture clear polyacrylic finish
    11/16

    mixed colors full rough texture clear polyacrylic finish

  • mixed colors full rough texture horizontal veneers engineered core no finish
    12/16

    mixed colors full rough texture horizontal veneers engineered core no finish

  • skip sanded mixed ID barnwood Waterlox finish roundtop
    13/16

    skip sanded mixed ID barnwood Waterlox finish roundtop

  • Plank Doors
    14/16

    Plank Doors

  • skip sanded mixed oak random width horizontal veneers
    15/16

    skip sanded mixed oak random width horizontal veneers

  • Reclaimed wood exterior door, window, engineered foam core
    16/16

    Reclaimed wood exterior door, window, engineered foam core

Like our stile and rail doors we take special steps to ensure quality construction:
 
  • Zero VOC and formaldehyde free glues, Type II water resistant glues.
  • Veneers are ¼ - 5/16” thick. Planks can be chosen for all different widths and orientation can be vertical or horizontal.
  • All edges are made from solid wood.
  • Cores are a combination of at least three sheets from two of the following categories: hardboard over foam core, birch plywood, or lumber core plywood.  This combination helps to produce a truly flat product and will also minimize movement or warping, something that can be an inherent problem with this type of design.  The foam core helps to reduce weight and add insulation value.  The birch ply provides strength, stability, and tensioning.  These cores are all concealed, and there is no way to tell that they are in the door without cutting it in half.
  • Option to not have an engineered core but rather just two boards face glued together to make a plank and then edge glued to other planks.  This technique is only recommended for interior sliding doors and is not as stable as the engineered option.
  • All doors with sanded texture are finish sanded to 150 grit, but final sanding should be done again by customer.
  • Unlimited combinations for dimensions and embellishments.
  • Satisfaction of knowing that your door was made entirely in America with local products. You can hold us accountable for your satisfaction because you are ordering direct from the craftsmen who build your product.