Internal Doors

**patty** · 16th April 2008, 11:22 PM

Hi All I was interested to know if anyone has ever attempted to make internal doors I have a little bit of a dilemma when my father in law built the builtin wardrobes in our 3 bedrooms he used standard 2040 x 820x 35 hollow core internal doors just the 4 panel cheapies you can get at Bunnies for 35 bucks but the problem is the ceiling height is 2600 so i have a 600 mm infill panel at the top and it makes it a pain in the ???? to store and aceess stuff and it is general wasted space.... I have priced up 2340 taller doors but the price came back at $130 dollars each

surely hollow core doors cant be hard to make they basically look like a frame on the outside and a small batton through the centre and filled with cardboard and cladded both sides in 6 mm i think mdf am i being naive considering this.. Im no tight ???? but 130 bucks for each door is pretty rich considering i need to replace 4 of them

Any ideas

**SilentButDeadly** · 17th April 2008, 12:50 PM

Patty
a sheet of 2400x1200 4mm BC grade plywood will set you back around $50-60.....and you'll need two sheets to do one door.....plus some hardwood for the frame...

On the other hand...you could get a sheet of 32mm MDF in 2700x900 for about $90 but it'd weigh 60kgs.......failing that a 2700x1800 sheet of 9mm MDF can be had for under $50 I think.

However, http://www.hardwarestore.net.au/Hume...nal_doors.html has the Hume doors in 2340 tall and multiple widths listed at $84....

**patty** · 17th April 2008, 07:09 PM

thanks for the reply SBD, How a door 340mm taller can cost nearly 4 times as much as a standard 2040 hollow core internal is Highway robbery, well I guess its all about supply and demand you pay a premium for odd sizes!I was expecting double the price but certainly not what i was quoted , I was quoted $133 bucks from Doors Plus and $128 from Bunnies from a friend of the family but in all its still a rip off though!!

**Master Splinter** · 17th April 2008, 07:55 PM

The cheap solution is to buy a few extra 2040x820x35 doors, cut into 600mm high sections, fill the exposed core edges with a piece of crapiata ripped to size (the cardboard honeycomb inside shifts out of the way with a sharp chisel, glue and clamp the new edge piece in) and you're done.

Yes, you end up with twice the number of doors, but you get it for less than half the cost!

**patty** · 18th April 2008, 05:38 PM

Thanks for the reply MS the thought of extending the door by 300 mm in the Middle had crossed my mind but then I would have 2 joins 150mm apart and might become a bit unsightly ,then I have thought about possibly extending top and bottom where i could possibly hide the joins a little better! the other thought was to strip the panels off the doors leave the existing frame extend the frame by 300 mm then clad both sides then no joins does anyone know the material they use for Internal doors it looks like 5 or 6mm mdf

**Master Splinter** · 18th April 2008, 08:43 PM

It's not worth the effort to try re-skinning - you end up tearing the cardboard honeycomb stuff into shreds and you have to replace it with something otherwise the doors flex too much.

If you are thinking of making up your own door, its not too hard, just make sure you have a big flat surface to do it on. Maybe bandsaw up some corrugated cardboard to use as internal stiffening without adding too much weight.

Or - add an extra section to the existing door but don't try to disguise the join, just leave it looking like a divided panel.

Aluminium sliding wardrobe doors??? I think they are easy to get in silly heights.....

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