I am thinking about building an entry door for our future house, it would be out of mahogany (South American). Would this work, doing the 3 layers would give huge glue surface area for the joints and separate the outside and inside wood. The panels would be thinner solid wood (like 1/2") and a separating layer of ridgid foam to keep the door solid & insulated. The 1/2" panels would be floating so they could move.
I can't really do the stave core and glue laminate on top of that, don't have the proper tools to do it right. The other option would be 2.25" solid wood for the rails and styles, but worried about it warping & finding straight boards to start with.
Here is a little drawing of what I am thinking. Done a lot of reading but sounds like most do a stave core with thin laminate, would 1/2" material on the stave core be too much (ie, movement tear apart the core)?
Thanks