Thread: Best Material for DIY large doors

How about pine framed plywood.
you are going to paint them... so dont waste anythiing pretty of expensive.

pine will be cheap, light and easy to work. 10mm bb hoop ply will be similar and dimensionaly stable. and a convienient size to rout slots for.



Cheers

I'd just use ordinary flush panel house doors.
Shorten the doors that will be used for the top.
Its pretty easy, just take your time & do it neatly.
Cut the the doors off to desired length.
From the offcut remove the original top rail.
You will need to remove every bit of the original door skin, use a sharp chisel or handplane
Push the cardboard honeycomb down from the top so the top rail will go in.
Apply glue to front & rear sheets and push the rail in till its a perfect fit.
Apply clamping boards and clamps and wait till the glue sets.

In the old days I've seen 3mm masonite used on a pine frame, but they always warp in a decade or two... We have VJ walls in our house so I used 6mm mdf with vj grooves cut in the front, tacked and glued onto pine frames. I'm sure 6mm ply would do the same job. Ours have been in 3 years now, and they look great. I wish I'd taken the time to hide the hinges though! Our ceilings are 3.2m high too so the lower section is about 2m with a smaller door on top. We are lucky enough to have a 100mm dado rail about 2m up so I used that as the break. If I was doing them again I'd put in ajustable shelving too - Bunnings sell melamine sheets with the holes pre drilled to take shelf supports.

Hi Nicolas
I'd go along with Bob's idea of using standard hollow core doors.
Or, have you thought about sliders? Mdf would be OK then, the weight on the bottom tracks.
Regard
Bill

Thanks for all the sugestions. I think I'll try the idea of using standard doors.

Thanks again