Door lining not wide enough?

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plugy

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Cheshire
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we are converting our garage and will need to replace the door and lining (the original door + lining never fitted) however it appears the off the shelf linings are not wide enough.
On the assumption of 100mm thermalite, 12mm boards, dabs 10-20mm walls a little out and 3mm skim, making the wide between 150-160. Your B&Q etc only carry 132mm frames. what are the best options, make one, trawl internet for wider frames, or tack stripwood onto the 132 frame to pad out? Any thoughts?
 
Go to a proper timber merchant to start with- they may have oversize sets (160 isn't massive).
If they don't you can make your own - again with timber from timber merchant. I've done several- 20 x 200 board for the outer, 20 x 160 to form the recess for the door, glued & screwed.
Trick is getting the cuts dead square, a router and straight edge is very handy.
 
It's possible a single wide board will crack, when it shrinks as it dries out.

i suppose you could reduce the risk by running all your screws down one edge at first, and screwing the other edge later. There may be a better way. In grand houses with very thick walls, the door lining may be a panelled assembly made up by a joiner to allow movement. Today I suppose you could use ply.
 
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