Moving ahead with a flush panel exterior door project and would like some more opinions.
It will be flush door covered with a single sheet of commercial ribbon striped mahogany and have several round glass windows.
The core is baltic birch 1/2 inch on either side with another 2 layers of 3/8 and 1/4 to get me close to a final thickness of 1 5/8 inches. Planning to bond it all together with epoxy or Weldwood 2 part plastic resin glue. Opinions on which is better? Pretty sure most will say the epoxy. Will glue it up in a vacuum bag.
Considering making it more hollow with some rigid foam insulation that would bump the door R value up a bit and of course make it lighter. The house is a 50 year old mid century modern that has been improved but not nearly as tight as newer homes so the insulating value isn't that huge of a deal. Locally available sheets are not 5/8 inch so that is another concern.
Finally, the glass will most likely just be 3/8 laminated glass . IGU I have priced are about twice the price and may not matter that much.
So the questions or concerns would be:
1. Epoxy or plastic resin glue?
2. Hollow-ish with foam, and what kind, where to source it, etc. or solid?
3. How much larger than the glass should the window openings be and how (aside from silicone) to center the glass in the openings? Would you use IGU's?