How to Add Veneer Plywood to a Blank Door
- 1). Sand over the door blank surface using 150-grit sandpaper. This will slightly scuff the surface, creating a better bond for the glue and veneer. Wipe over the surface with a soft, clean cloth to remove dust when finished.
- 2). Pour some polyvinyl acetate glue into a tray or pan. The exact amount depends on the surface area of the door; you can easily add more glue to the pan, so don't worry about not pouring enough.
- 3). Thin really thick PVA glues, adding 1 part water to 9 or 10 parts glue. There are a wide variety of PVA glues, from white glue to various carpenter's glues and specialty products, all with varying consistencies. Thinning the glue slightly helps make it spreadable, but too much water will absorb into the door and veneer.
- 4). Dip either a rubber roller or a foam roller in the glue. Spread the glue across the face of the blank door slab. Apply a thin, even coat. Work the roller in various directions to ensure the glue covers the door face adequately and gets down in the pores.
- 5). Wait 5 or 10 minutes to allow the glue to soak into the wood. Apply a second, thin coat on top of the first, leaving just slightly more glue around the door edges. This ensures that all the glue doesn't soak into the door, leaving none to adhere the veneer, and that the edges will have plenty of bonding power.
- 6). Align a sheet of veneer, cut to size, with the blank door slab. Lower to the door surface and press into position.
- 7). Roll over the entire surface of the veneer facing, starting at the center of the door and working outward. Use a clean rubber roller and apply firm pressure. This helps eliminate air bubbles that may interfere with a good bond.
- 8). Cover the veneer facing with a thin cotton sheet, brown paper sack or newspaper to protect the surface. Run a hot iron over the entire door, again working from the middle outwards, applying a firm and steady pressure. Adjust the final position of the veneer as you work. Heating up the glue in this manner dissipates any excess moisture to help accelerate drying time.
- 9). Place a sheet of plywood or a similar material on top of the door to protect the finish. Clamp the veneer to the door, spacing the clamps approximately every 6 inches. Allow the door and veneer to dry several hours before trimming the edges, as needed, with a utility knife, cutting out the knob and hinge areas and applying a finish.
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