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. Note that the face side can be placed on the inside or the outside of the door.

Step #2

A back should be cut slightly oversized to allow for trimming once the door is formed. This back should be a material that is close to or equal in strength to the face.

Step #3

A standard PVA glue should be applied to the inside of the back. This will be placed on the form and the Timberflex or Flexboard will be positioned over the back allowing the back to extend past the face on all edges. The panel should be pressed for the time recommended by the glue manufacturer.

Step #4

Once the panel has cured, the back edges can be trimmed by use of a hand router or saw.

Step #5

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 and back can then be covered with the desired materials to give you  a finished door. Any machining for concealed hinges or hardware can now be done.