Shaker doors with solid core and methods for making thereof

A shaker door, comprising:

• a) a rectangular frame;
• b) first and second molded door facings attached to opposite sides of the rectangular frame, the first and second door facings respectively comprising first and second raised peripheral regions opposite to one another, first and second transitions opposite to one another and surrounded by, immediately adjacent and perpendicular to, and contiguous with the first and second raised peripheral regions, and first and second recessed panels opposite to one another and terminating at opposite sides and opposite ends thereof at continuous planar outer perimeters that are surrounded by, immediately adjacent and perpendicular to, and contiguous with the first and second transitions, an entirety of the first and second recessed panels within the continuous planar outer perimeters being planar and recessed from the raised peripheral regions, the first and second door facings and the rectangular frame defining a cavity;
• and
• c) a core contained in the cavity, the core comprising:
• i) a first core comprising a first member and a second member, the first member of the first core having a first density and being disposed between the first and second recessed panels but not extending beyond the continuous planar outer perimeters of the first and second recessed panels, the second member of the first core having a second density less than the first density and being disposed between the first and second raised peripheral regions but not within the continuous planar outer perimeters of the first and second recessed panels;
• or
• i) a second core comprising a first member and a second member, the first member of the second core spanning substantially an entire length and width of the cavity and having a thickness sufficient to fill an area of the cavity between the first and second recessed panels, the second member of the second core comprising first and second layers on opposite sides of the first member of the second core and being disposed between the first and second raised peripheral regions but not within the continuous planar outer perimeters of the first and second recessed panels;
• or
• iii) a third core comprising a first member and a second member, the first member of the third core being disposed between the first and second recessed panels and comprising an overhang extending beyond the continuous planar outer perimeters of the first and second recessed panels, the second member of the third core being disposed between the first and second raised peripheral regions but not within the continuous planar outer perimeters of the first and second recessed panels, the second member of the third core having a channel receiving the overhang of the first member of the third core;
• or
• iv) a fourth core comprising a first member and a second member, the first member of the fourth core being disposed between the first and second recessed panels and comprising an overhang with opposite overhang surfaces extending beyond the continuous planar outer perimeters of the first and second recessed panels, the second member of the fourth core being disposed between the first and second raised peripheral regions but not within the continuous planar outer perimeters of the first and second recessed panels, the second member of the fourth core having an L-shaped cross section with a ledge contacting one of the overhang surfaces and providing a void at the other of the overhang surfaces.