I'm considering building my own doors from scratch, especially since I need custom sizes.
One thought is to use two layers of 3/4" MDF, screwed together, perhaps with Green Glue inbetween the layers. Then glue 1/4" paneling to both sides (to cover the screws)... this would be 2.00" thick in total, just a hair thicker than a standard door, I'd hope that most standard hardware would fit nicely.
And 3/4" MDF... not sure of the exact PSF, but I believe it's about 3.0 PSF... so, the door in total would be about 6.0 PSF, would match or be of even greater mass than my walls... sweet.
Has anyone made doors of MDF? I've never used MDF before, just wondering if it will hold screws well (as in the screws that would hold the hinges from the sides). I know with other man-made materials (like OSB for instance), screws will NOT hold well when driven in at the sides... even plywood for that matter (the plys tend to separate if screws are driven in at the sides, etc)... I am hoping that MDF will take screws well from the sides (assuming proper pre-drilling and use of good long heavy-duty screws). Before I go out and buy several sheets of MDF, can anyone confirm?
If anyone has built doors of MDF from scratch, I'd love some details.... pics too if possible... OR, I'd surely welcome any other ideas in terms of DIY heavy-mass doors.
Thanks
