2520 wooden door Question

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mlc20

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I have removed the door off my 2520 because the middle panel seems to be in rough shape.Has anyone replaced the middle panel before. I am wondering what the best approach of getting it out is. Not too good with wood. I also noticed that its glued together and there are no nails.
 
Pics of door. It seems like the wooden panel is delaminating anyone have this problem
 

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I would repair with West Epoxy mixed with sawdust.

After you sand and varnish or whatever, you will barely notice it.
 
FWIW Raka epoxy is 1/2 to 2/3rds the cost of West Systems and by my experience and that of others, it's just as good. A bonus is the straight 2:1 mix of resin to hardener, so no expen$ive pumps are needed. I've mixed from 2-to-1 capfulls to 8-ounce yogurt containers ... and it works slick! See www.raka.com and call or email Larry @ Raka if you need specific guidance. He's awesome to deal with!

That said, my door is worse than yours. I did what others suggested, I warmed the door with a slightly damp cloth and used a clothes iron to iron flat the pieces. Then I injected epoxy into the cracks, covered the bad area with wax paper sprayed with Pam cooking spray with olive oil (as a release agent) and left some 'heavy' items on it to cure so the delam would lay flat. CAUTION: You need to have the door OFF and make sure you have the entire OPPOSITE site of the door supported, NOT the frame. Otherwise you will get a bulge.

This will work and last you a few seasons, but once water gets int ehre ... it's only a matter of time 'til you will eventually replace it. I'd say, looking at yours, if you do as I suggest (there may be other methoids) you might even fix it but good, as mine was much worse than yours when I effected my repair and I still got 3 season out of it, maybe 4. Make sure to seal the OTHER side too, as moisture is insidious and will get in however and wherever it can.
 
Thanks for all the good info but the picture doesnt show just how bad it is. Im afraid i have to replace it though because both sides have the delaminating issues. The picture i showed is only of where the wood is cracked through but both sides the wood has become wavey. Cant really see it in the pic. Is there a good method of getting the wood unglued or do i have to have a new one made? :oops:
 
I think Grouperjim had his starboard door for sale, I wonder if he still has it.

May look a little off on a vintage Parker though.
 
well i would like to keep the wood door because the door is really solid. all the wood on the door is in great shape except for the middle panel. i just find it odd that only the middle panel would fall apart. im thinking of cutting the panel out and trying to pop the bottom part of the door off. then remove the rest of the wood and have a new piece made. im just not sure how strong the glue is. I will let you guys know how it comes out and try to take pics along the way
 
I plan on cutting out the center, using a router or chisel to clean the inside edges of the frame. Then I will make some mahogany trim and put a border on one side. New panel goes in, then new trim holds it in on the other side. All pieces to be fully encapulated in epoxy.
 
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