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How to Build a High-End Stile and Rail Impact Door

Being in the business of helping the biggest door manufacturers and high-end millworks building the best doors in the world, we thought we might let you in on a little secret. Sing Core is world renowned for building the best enormous doors that are lightweight, high strength, fully insulated, and guaranteed to perform warp-free for 50 years. But did you know that we also make the world’s strongest lightweight and insulated stile and rail doors?

The popularity of stile and rail doors has been around for years because, number one, they look amazing. They have a unique appearance as they are manufactured of panels of various sizes. The most popular, and it is the one you are most likely to think of when you think of a stile and rail door, is the six-panel door.

Hands down, this is by far the most popular design. The traditional six panel door is made up of 15 individual wood pieces with alternating grain orientation and all the components are assembled by varying means depending on the application of the door.

If the best feature of the stile and rail door is the undeniable appearance of the door, the second-best feature of the stile and rail door is it’s ability to stay relatively straight over the life of the door. This is accomplished by varying the grain orientation of all the individual panel pieces, which push and pull against each other, unlike a traditional solid slab door which can move wildly at any time or according to any change in the environment.

But the biggest disadvantages include very low insulation value. This means they are not well suited for climate control or sound reduction, and for high-end clients, though they love the appearance of the panel doors, they are not very strong.

If you build stile and rail doors, you may need to know how new technology can lower your labor costs and increase your productivity when building all types, styles, and designs of doors. Sing Core has done it and proven it backed by the best guarantee in the industry.
We can help you:

  • Meet your production needs – Fast Delivery
  • Exceed your quality expectations – High Precision
  • Reduce your labor cost – Money Saving
  • Structural guarantee – 50 Years!
  • Custom sizes – Any Size or Weight
  • Fully insulated and sound deadening door panels

The Sing solution is to build your stile and rail door on top of the patented Sing Panel Door Substrate invented by Peter Sing. Sing’s substrate is lightweight, high strength, fully insulated and comes back by the only

50-year Warp-free Guarantee

in the door industry.

Now, you do not have to settle for a weak stile and rail door because your stile and rail door can have Sing Core inside.

How to Build a Stile and Rail Impact Door

The first step is to start with Sing’s patented core which is built of small metric vertical grain torsion box where the voids are filled with foam for insulation, and this is sandwiched between two stress skins.

The next stage is where the expertise of the millworks and door manufacturers come in. Instead of manufacturing the door out of individual pieces of wood stuck together, the panel design elements, as in our six-panel door option shown here, are added to the surface of the door.

This gives you the appearance of the traditional six panel that we all have come to love, but if your six-panel door has Sing Core inside, you have the lightweight for panel doors of enormous size, or adjustable weight for smaller doors, with all the insulation and incredible unbreakable strength.

Sing says, “If you kick a traditional stile and rail door you will break the door, but

“If you kick my door, you will break your leg.”

(Don’t try this at home.)

This is just the beginning. Sing can help you make any kind of door. Sing Core is featured in all kinds of doors and is highly sought after when creating replacement doors is historical restorations, especially if they are large doors which are problematic for maintenance because they do not have Sing Core inside. We do not sell our products to homeowners, door stores, or door shops. We do not sell our products to general contractors without door finishing facilities or capabilities. We mainly deal with door manufacturers and millworks which have experience to build high-end doors.

Problem Solved.

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Sing Stile and Rail Doors

The Sing-style approach to stile and rail doors is a horse of a different color amidst the age-old door industry. Sing stile and rail doors are lighter in weight and stronger than steel yet made of nearly any flat building material available, not matter how they’re built.

Sing Stile and Rail Look

Our most sought-after stile and rail manufacturing method produces a stile-and-rail-looking door from a solid composite Sing door slab which feature alternating wood grain orientations on the door surface to emulate the look and feel of a stile and rail door without any weak spots.

The resulting Sing Stile and rail door made of a solid door panel is the strongest, lightweight, most insulated, Eco-friendly door proudly made in the USA.

Sing Stile and Rail Construction

Even among the most tried and true stile and rail door manufacturers, they know that the only way to build a large stile and rail door which can be guaranteed not to warp for 50 years, is with Sing Core inside.

Rather than build a stile and rail looking surface and applying it to a solid slab of Sing Core, traditional stile and rail manufacturers prefer to use stile and rail components with Sing Core inside.

Basically, this means that all the stile and rail components are manufactured by Sing Core in building material formats which are very similar to our post and beam configurations, and/or furniture panels. These are assembled by your favorite stile and rail door builder just as they would any traditional wood stile and rail door components.

Sing Stile and Rail Advancements

You might be surprised what benefits can be enjoyed by custom door makers who construct their doors using patented Sing products. This new, revolutionary door building material is

Lightweight Stile and Rail Doors

Weighing in at a fraction of other solid core doors, Sing stile and rail doors can be very lightweight, even if they are very big doors, without threatening the longevity of the door’s performance over time.

High Strength Stile and Rail Doors

Stile and rail doors made of Sing Core are incredibly strong. Rated at 660 PSI, Sing Core is stronger than steel pound for pound, thanks to Peter Sing’s patented solid composite torsion box core substrate, incredible unsupported spans are possible, enabling doors with Sing Core inside to outperform any other lightweight door.

50 Year Stile and Rail Guarantee

Professional grade Sing Core has such a high precision tolerance (+/- .006 in.) and withstands just about any variance in conditions across the board, that these are the only door which can be guaranteed not to warp, bend, twist, or otherwise fail for 50 years, including full structure warranty.

Eco-friendly Sing Core

Using Sing Core is the Eco-friendliest way to build a sustainable door, which is made with a smart combination of minimal natural and recycled material combined to create this revolutionary door core material which is the lightest weight and highest strength way to build doors of any kind.

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Door Stile Rail

Applications -> Building Components -> Doors -> Sing Stile and Rail Doors

Sing Stile and Rail Doors

SINGCORE-The new generation of door making is an alternative to the old stile and rail door which has dominated the market for the last 100 years.

 

torsion box, sandwich panel, honeycomb panel, lightweight panel

Patented Sing Core: We put a torsion box in the SIP panel to make it better. The other names for our panels include sandwich panel, honeycomb panel and lightweight panel.

The new technology developed and patented by inventor Peter Sing makes doors stronger ,more lightweight, saves more energy and is more dimensional stable than any stile and rail door. Best of all it is more affordable due to the reduction in labor used to produce Sing Panels and that savings is passed down to you and your customers.
The new Sing torsion box door frame is labor saving, earth friendly, the best of all it makes for a long lasting door.

Our Sing Stile and Rail Doors fill a need in the sliding glass door niche because our cores are not only lighter than standard solid wood, fiberglass and composite door cores but our cores are stronger providing a longer lasting door core with a structural guarantee of 10 years which is about 9 years longer than the standard guarantee out there.

Sing Honeycomb Oversized Door Finger PushIt’s so easy to use Sing Panels to make beautiful doors of any size. Sing Door Panels have a ten year warranty for interior use. For external use, we offer marine grade plywood. If you need strength, lightweight, insulation, and true flatness, Sing has the answer!

How to Buy

Sing Door Panels are easy to order.  You may choose from our stock panels or order custom sized panels. Our price is based on the length, width, thickness, and quantity. Submit a Work Order by fax or email, and we will give you a quote within two business days.

Sing Door Products

Carriage Doors
Sliding/Pocket Doors
Interior
Exterior
Overhead

 

Get custom doors without the custom pricing!

Sing Honeycomb Panels are available at a fraction of the price of conventional sliding door panels, and require half the work. Sing Door Panels are insulated, lightweight, strong and more dimensionally stable than solid wood panels!

Choose Sing for all your Door Panels!  When using Sing Panels, you design your own door by adding the trim, paint, and hardware. Sing Door Panels are great for millwork shops and door builders. Special pricing is available to distributors and retailers.

The typical 1.5″ solid wood edging is adaquate for door hinges but add solid wood blocking to your door core for added hardware or door knob needs.

Order the typical flat panel door or add trim to the panel to achieve the raised panel look.

Skin Options

To see typical skin options click here.

How to Order

Stock Doors Available:
Sing Door Panels (4’ x 8’ or smaller) just fill out the order form.

Order Custom Sizes:
To order custom doors sizes, submit an order form. We’ll respond with a quote within two business days.

How to Install the Glass

 

 

SINGCORE sliding glass doors can do anything a traditional stile and rail door can and more.

How to build.

On the left are patented Sing honeycomb stile and rail. On the right is veneer (walnut) ready for gluing onto the patented Sing honeycomb stile and rail.

 

Apply glue to our patented Sing honeycomb stile and rail.

 

Press veneer to patented Sing honeycomb stile and rail. Most honeycomb panels cannot handle the high pressure and temperatures of the hot press, Sing honeycomb can.

 

Stile and Rail after the veneer has been pressed on.

 

See how straight the patented Sing honeycomb stile and rail are, yet they are still incredibly strong and lightweight.

 

Drill holes to accept dowels.

 

Doweled and glued.

 

Router out the end if hardware is to be installed

Stained and ready for glass and installation.

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