Foam-filled door and method of manufacture

A door, comprising:

• a frame;
• said frame having two ledge areas extending about substantially the entire inner periphery of said frame;
• each of said ledge areas having substantial depth and substantial width;
• first and second facers engaging said frame and forming a cavity between said facers and said frame;
• one of said ledge areas being proximate to one of said facers;
• the other of said ledge areas being proximate to the other of said facers;
• said frame including a pair of spaced, substantially parallel rails and a pair of spaced, substantially parallel stiles, each of said stiles being disposed at substantial right angles to each of said rails;
• stile flanges connected to said facers at substantially 90 degree angles to said facers;
• rail flanges connected to said facers at substantially 90 degree angles to said facers;
• said stiles having grooves positioned outward of said ledge areas for receiving said stile flanges, said grooves being substantially normal to said facers;
• each of said rails having an outer surface, said rail flanges of said facers engaging said outer surface of said rails;
• said ledge areas extending entirely along the length of each of said rails and each of said stiles;
• said ledge areas forming vents between said rails, stiles, and said facers, said vents each extending between said cavity and the atmosphere external to the door, said rail flanges extending substantially along the entire length of said rails without covering said vents;
• and
• foam material substantially filling said cavity and said ledge areas to form an adhesive gasket between said frame and said facers such that said vents are substantially permanently sealed by said foam material.