Sorry about the new thread, but I marked the thread as read and
then decided to reply. In a previous home, I had a 42" doorway 8'
tall between a storage room and my garage. I wanted the large
opening to move equipment in and out easily and had no intention
to pay "whatever" a commercial door would cost. I made my own
door using 2 sheets of birch faced high density board, together
with a single sheet of MDO in the middle. The door was thus
2-1/4" thick. For interest, I routed in, using a 3/8" veining
bit, detail that simulated a 5-panel door.
My concern was the strength of the particle board material when it
came to holding the hinges I felt I needed. To solve this, I
stood the door upright on my table saw <shudder> and my neighbor
and I used the blade fully extended to cut a kerf in the center of
the hinge edge of the door. I centered the kerf and inserted a
full length piece of 3" wide, 1/8" thick steel, screwing it fast
from the store room side in probably 20 locations along the door.
Then, I used overlay (gate-type) hinges to hang the door, bolting
through the door and its steel insert.
The rest was just typical addition of hardware, using an extended
rod between the knobs.
On most days,
it's just not worth
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