I'm building a huge closet at a client's beach house. It's in a tackle room actually. Four 54" wide by 7'6" by 1.5" thick bypass barn doors in cypress. I try to use air dried lumber but it seems my source hasn't been able to air dry as long as usual because of increased demand for cypress with construction wood being so insanely high. 5.5" stiles, through tenons with wedges on the 3 rails (5.5", 6.5", 7.5" top to bottom), floating 6" v-edge panels.
Well, 2 doors warped. Not a lot but over such a big door, it has a big impact. First, any thoughts on a fix? Obviously, rebuilding is an option but chances are it will happen again and these are pretty labor intensive and a pile of wood.
And what are your thoughts on this;
If I route a channel (a couple of inches from the outside so most of the joinery is still in tact) 1-1.25 deep, maybe an inch wide or less. Clamp it straight or maybe even over compensate for the bow and screw a piece of flat bar or angle to the inside of the groove. Then fill it with epoxy or plug the rest with wood. The inside won't be seen and the clients would be fine with it. And they are hanging from barn door hardware so hinge stress won't be an issue. Just wondering if you think that will hold it straight.
Any thoughts would be appreciated, especially if it helps me sleep at night.