Making an internal door from MDF?

[Henrik]

Hi,

need to replace some internal doors which have become badly warped. Received some off the wall quotes from local joineries to make (old style door not in use any more, with mouldings), so am toying with making my own. Don't have enough equipment to make my own from timber, but has anyone made doors from MDF? Am thinking of using 22mm core, and using 12mm either side to recreate stiles/rails, finishing off with some routed mouldings between 22 and 12mm surfaces to create panel effect. Painted then to finish.

Anyone have any views? Have seen cabinet doors made this way, but does it realistically transfer to full size doors? Appreciate all inputs!

Thanks,

Henrik

 

[Jasonb]

I've done it on several occasions to match non standard doors.

Weight is an issue so I use Ultralite MDF, there are several other brand, these are about 2/3rds the weight of standard MDF. I then machined mouldings to match the existing and applied they as you describe.

I also make the core MDF about 25mm smaller than the opening and the outer layers 6mm smaller on each side and then machine a "T" shaped hardwood lipping that is glued into the resulting channel. This gives a nicer edge and makes cutting in hinges easier.

Couple of examples of MDF doors here, here and here, the sliding one not the shower

Jason

 

[Henrik]

Jason,

thanks for that - good to know I'm on the right track. Thanks also for the tip about lightweight mdf.

Do you have any more photos of your work I could look at?

Regards

Henrik

 

[Jasonb]

My photobucket account has both Work and hobby pics here.

Jason