Step #1

Cut the Timberflex or Flexboard to the desired size of the formed door. This is best done by having a cross-section drawing of the door and taking a small strip of the product to determine the needed width. The Timberflex or Flaxboard face side will be placed on the inside of the door.

Step #2

A face should be cut slightly oversized to allow for trimming once the door is formed. This face should be a material similar to the Timberflex or Flexboard when possible. If this is not possible, then select a face that is close to or equal in strength to the material

Step #3

The form for this process should be made of ribs that will provide the radius required to produce the correct size door. Remember that these ribs must allow for the thickness of the Timberflex or Flexboard, as this will be the inside radius of the door. You will need a support rib about every 6" to provide the needed support (Fig. 1).

Step #4

Place the Timberflex of Flexboard face down on the form, making sure you have a rib or support where the edges of the door are placed.

Step #5

Cut the face material so you will have approximately 1/2" overhang on all edges.

Step #6

Spread a moderate amount of PVA glue on the rib side of the TRimberflex or Flexboard and the back side of the face material.

Step #7

Use a scrap piece of Timberflex or Flexboard to place over the face to help distribute the pressure evenly over the door. Strap this assembly in place with belt clamps. The use of a scrap piece of wood at the vertical edges of the assembly is recommended to help provide adequate pressure of these critical edges. Allow the glue to dry as recommended by the manufacturer. The overhang edges can be trimmed using a hand router (Fig. 2).

Step #8

The top and bottom edges can then be covered with the desired material to cover the open kerfs. This can also be done to the vertical edges if desired. The face or back can then be covered, if needed, with the desired materials to give a finished door. Any machining for concealed hinges or hardware can now be done.