today the carpenter came to install my doors.
there is a big gap between the door assembly and the wall.
at some places its nearly nothing but at other places its more than an inch...
i could just stop him from spraying pur-foam in it!!
how could i fill this place up?
Horrible. Expanding foam is also vile. How about concrete? I don't have enough build experience to predict drying issues, but I reckon you will be skimming over it later anyway.
Perhaps you could make up something with PVA glue and wood chips and sawdust? A sort of DIY plastic wood?
My sympathies, but sort it out properly, as in airtight.
I'd say, it's a great example why contractors are the weakest link in studio construction.
But even the best efforts to build tight framing usually results in gaps and opening that have to be dealt with.
One of my own doors has similar issues... and I helped frame it myself. It was framed overall 1/2" wider than I thought I had framed it. So that means I had to deal with a nasty 1" gap on the latch side.
Framing is never perfect, and you have to deal with the problems that arise.
The reality is that the "best" solution is rarely the "easiest" and compromising often yields less than desirable results.