I'm building a new entry door for my house in northwest Pennsylvania, and it's going to be under a covered porch, so it won't be exposed to rain or snow. I've been looking into using a solid core to help avoid warping. What materials would you recommend for the core? I was considering MDF, but I'm open to suggestions!
1 Answer
I really wouldn't recommend MDF for a door core. It's not stable enough for that kind of application. I'd suggest going for a finger joint lumber core or an LVL (laminated veneer lumber) core. You can often find these types at hardwood suppliers. You could also create your own lumber core using 3/4" poplar or something similar. Just glue it up, flatten it, and then plane it to width before attaching the skins.
I thought about using MDF because I found it listed as an option on several sites, which is why I asked here. Just trying to gather some recommendations!
What do you mean MDF isn't stable enough? It's one of the most dimensionally stable wood products out there! If you seal the edges and keep it dry, it doesn't swell or twist. The only issue is that it struggles with mechanical fasteners, so I'd use solid wood for the hinge and latch edges if it were me.