Joining Hollow Core Doors - Carpentry - Contractor Talk

Joining Hollow Core Doors

 
Thread Tools Search this Thread Display Modes
Old 03-15-2018, 07:01 PM   #1
New Guy
 
Hutch01's Avatar
 
Trade: Remodeling
Join Date: Feb 2018
Location: Cleveland
Posts: 24
Rewards Points: 64

Joining Hollow Core Doors


I'm currently working on a basement renovation, the client is pretty much at their max budget. They have a set of bi-fold doors spanning a 48" opening that leads to a home office. The ceiling is getting painted flat black, I'm trimming out the top of the drywall with flat casing.

Given that the basement will have an updated, somewhat contemporary look, I'd like to convert the exiting bi-fold doors to a barn door. Aside from glue, does any have suggestions on how best to secure all 4 panels into a single door given they are hollow core? I don't want to risk a return visit 3 month down the line if I can't come up with a good solution.
Hutch01 is offline  

Warning: The topics covered on this site include activities in which there exists the potential for serious injury or death. ContractorTalk.com DOES NOT guarantee the accuracy or completeness of any information contained on this site. Always use proper safety precaution and reference reliable outside sources before attempting any construction or remodeling task!

   

Advertisement

 

Old 03-15-2018, 07:19 PM   #2
Pro
 
Tom M's Avatar
 
Trade: GC/ Interior & Exterior Remodeling
Join Date: Jan 2007
Location: Bergen County, NJ
Posts: 8,436
Rewards Points: 7,106

Re: Joining Hollow Core Doors


How about pulling the hinges, pocket screw or dowel the side rails then run a solid piece of 5/4 across the top and across the bottom. Even angle iron if the inside is not visible. Thats a cheap option

Advertisement

Tom M is offline  
Old 03-15-2018, 07:32 PM   #3
Pro
 
Big Johnson's Avatar
 
Trade: Contractor and Grunt
Join Date: Jun 2017
Location: Michigan
Posts: 2,152
Rewards Points: 4,246

Re: Joining Hollow Core Doors


If they’re out of money it’s time to stop working. Not look for ways to cobble the rest of the job and be on the hook for said cobbles.
Big Johnson is offline  
The Following 9 Users Say Thank You to Big Johnson For This Useful Post:
Bull Trout (03-15-2018), greg24k (03-16-2018), Irishslave (03-15-2018), john5mt (05-17-2018), KAP (03-15-2018), MarkJames (03-15-2018), mrcat (03-16-2018), pinwheel (03-20-2018), tang (03-16-2018)
   
 
Old 03-15-2018, 07:37 PM   #4
Pro
 
MarkJames's Avatar
 
Trade: Handyman Services
Join Date: Nov 2012
Location: Arlington, VA
Posts: 7,212
Rewards Points: 13,515

Re: Joining Hollow Core Doors


Since it's modern, how about getting two hollow flat slabs and connecting those instead? Then there's just one joint to worry about vs 3 and less headache. glue, biscuits, pocket screws, etc.

I saw a new high end home get those and it was funny at the time....I wonder how they held up. The same house had a large steam shower bathroom with floor to ceiling glass walls on a 12x16 footprint. I guess that's where they burned their budget.
MarkJames is offline  
Old 03-15-2018, 07:42 PM   #5
New Guy
 
Hutch01's Avatar
 
Trade: Remodeling
Join Date: Feb 2018
Location: Cleveland
Posts: 24
Rewards Points: 64

Re: Joining Hollow Core Doors


Quote:
Originally Posted by Tom M View Post
How about pulling the hinges, pocket screw or dowel the side rails then run a solid piece of 5/4 across the top and across the bottom. Even angle iron if the inside is not visible. Thats a cheap option
I like the idea about running 5/4 along the top and bottom, and the dowels too.
Hutch01 is offline  
Old 03-15-2018, 07:52 PM   #6
back doors to hell put in
 
Irishslave's Avatar
 
Trade: Carpenter
Join Date: Jun 2010
Location: Google knows
Posts: 3,085
Rewards Points: 2,484

Re: Joining Hollow Core Doors


Quote:
Originally Posted by Big Johnson View Post
If they’re out of money it’s time to stop working. Not look for ways to cobble the rest of the job and be on the hook for said cobbles.
X2 out of money? then you're out of a contractor. period. Good luck finding someone to finish for free. If you find them let me know...I'll put them to work.
__________________
Television is fake...The internet is real
Irishslave is offline  
The Following 3 Users Say Thank You to Irishslave For This Useful Post:
Big Johnson (03-15-2018), Bull Trout (03-15-2018), KAP (03-15-2018)
Old 03-15-2018, 08:15 PM   #7
Pro
 
Big Johnson's Avatar
 
Trade: Contractor and Grunt
Join Date: Jun 2017
Location: Michigan
Posts: 2,152
Rewards Points: 4,246

Re: Joining Hollow Core Doors


Quote:
Originally Posted by MarkJames View Post
Since it's modern, how about getting two hollow flat slabs and connecting those instead? Then there's just one joint to worry about vs 3 and less headache. glue, biscuits, pocket screws, etc.

I saw a new high end home get those and it was funny at the time....I wonder how they held up. The same house had a large steam shower bathroom with floor to ceiling glass walls on a 12x16 footprint. I guess that's where they burned their budget.
My time to dick around with that would be more than the cost of buying a decorative barn door or two. Or (2) 24” slabs of my customers choice.
Big Johnson is offline  
Old 03-15-2018, 08:54 PM   #8
New Guy
 
Hutch01's Avatar
 
Trade: Remodeling
Join Date: Feb 2018
Location: Cleveland
Posts: 24
Rewards Points: 64

Re: Joining Hollow Core Doors


Quote:
Originally Posted by Big Johnson View Post
If they’re out of money it’s time to stop working. Not look for ways to cobble the rest of the job and be on the hook for said cobbles.
Whoa big fella, how does max budget equal out of money? Their basement is nothing but a kids play room, they're allocating money for other parts of the house.

Last I checked an off the shelf unit that size is at least $400, this wont take more than an hour of my time. I'm pretty happy with my daily rate, but it doesn't break down to $400 an hour.
Hutch01 is offline  
Old 03-15-2018, 09:36 PM   #9
Pro
 
Big Johnson's Avatar
 
Trade: Contractor and Grunt
Join Date: Jun 2017
Location: Michigan
Posts: 2,152
Rewards Points: 4,246

Re: Joining Hollow Core Doors


Quote:
Originally Posted by Hutch01 View Post
Whoa big fella, how does max budget equal out of money? Their basement is nothing but a kids play room, they're allocating money for other parts of the house.

Last I checked an off the shelf unit that size is at least $400, this wont take more than an hour of my time. I'm pretty happy with my daily rate, but it doesn't break down to $400 an hour.
If you’re so sure of yourself why are you asking us? You should be telling us...... “hey guys, look at this awesome basement I finished with kickass repurposed bifolds that saved my customers money and made me some bank.”
Big Johnson is offline  
The Following 2 Users Say Thank You to Big Johnson For This Useful Post:
john5mt (05-17-2018), pinwheel (03-20-2018)
Old 03-15-2018, 09:43 PM   #10
Pro
 
Tom M's Avatar
 
Trade: GC/ Interior & Exterior Remodeling
Join Date: Jan 2007
Location: Bergen County, NJ
Posts: 8,436
Rewards Points: 7,106

Re: Joining Hollow Core Doors


It is a contractor forum. Ideas..... Shop talk
Tom M is offline  
The Following 7 Users Say Thank You to Tom M For This Useful Post:
asevereid (03-15-2018), greg24k (03-16-2018), KAP (03-16-2018), onmywayup (03-16-2018), parkers5150 (03-16-2018), Rio (03-16-2018), SuperiorHIP (03-20-2018)
Old 03-16-2018, 06:44 AM   #11
General Contractor
 
greg24k's Avatar
 
Trade: New Home Construction-Additions-Remodeling
Join Date: May 2007
Location: NJ
Posts: 7,219
Rewards Points: 7,486

Re: Joining Hollow Core Doors


Get a 48" slab and call it a day.

Not only you will save your customer money and leave them with something that looks hacked up, you will save yourself some time dealing with BS.
__________________
I never lost a cent on the jobs I didn't get!
greg24k is offline  
The Following 2 Users Say Thank You to greg24k For This Useful Post:
Big Johnson (03-16-2018), KAP (03-16-2018)
Old 03-16-2018, 08:29 AM   #12
Pro
 
KAP's Avatar
 
Trade: Custom
Join Date: Feb 2011
Posts: 9,704
Rewards Points: 28,582

Re: Joining Hollow Core Doors


Quote:
Originally Posted by Hutch01 View Post
I like the idea about running 5/4 along the top and bottom, and the dowels too.
Quote:
Originally Posted by Hutch01 View Post
Whoa big fella, how does max budget equal out of money? Their basement is nothing but a kids play room, they're allocating money for other parts of the house.

Last I checked an off the shelf unit that size is at least $400, this wont take more than an hour of my time. I'm pretty happy with my daily rate, but it doesn't break down to $400 an hour.
It's not just an hour though right? Even employing a solution like Tom mentioned above, unless you have leftover material onsite from another phase of the projects you're doing, you still have to get the materials (there and back), setup/breakdown to be able to work the doors, cutting, gluing, clamping, nailing, filling, sanding, prime/paint, then re-install... if you can do all that in an hour, hat's off to you, but my guess is more like a minimum of half-day when all is said and done... even if your daily rate is only $400, that's $200 in labor PLUS materials someone has to pay for... keep in mind, it's still only going to look like an applique because it's not going to have the traditional features that most people associate with a barn door...

You might want to instead consider doing yourself and your customer a solid and selling them on a just getting a new door...
KAP is offline  
The Following 3 Users Say Thank You to KAP For This Useful Post:
Big Johnson (03-16-2018), tang (03-16-2018), Tom M (03-16-2018)
Old 03-16-2018, 09:27 AM   #13
Pro
 
hdavis's Avatar
 
Trade: remodeling
Join Date: Feb 2012
Location: CoastalME
Posts: 20,400
Rewards Points: 1,783

Re: Joining Hollow Core Doors


This isn't going to look like a barn door, and looks is the most important thing. You can get a decent look with 2 sheets of beadboard and a basic wood framework.

Last edited by hdavis; 03-16-2018 at 10:32 AM.
hdavis is offline  
The Following User Says Thank You to hdavis For This Useful Post:
Big Johnson (03-16-2018)
Old 03-16-2018, 09:57 AM   #14
Designer/Contractor
 
Rio's Avatar
 
Trade: General Contractor
Join Date: Oct 2009
Location: San Diego city/County, Cali
Posts: 2,770
Rewards Points: 2,340

Re: Joining Hollow Core Doors


Here's a photo of a faux barn door, these were originally 3' wide hollow core by-pass closet doors. That's stained cedar fencing that was glued screwed and tattoed onto the door(s). It's worked great and was inexpensive.

I think something like that would be an affordable alternative and would cost less than trying to get the door pieces to all stay together in plane.
Attached Thumbnails
Joining Hollow Core Doors-cheap-barn-door.jpg  
Rio is offline  
The Following 2 Users Say Thank You to Rio For This Useful Post:
Artworks (03-18-2018), pinwheel (03-20-2018)
Old 03-20-2018, 07:35 PM   #15
Contractor
 
AustinDB's Avatar
 
Trade: Remodeling & Home Additions
Join Date: Sep 2006
Location: Austin, TX
Posts: 4,153
Rewards Points: 766

Re: Joining Hollow Core Doors


if it's a 48" opening AND a home office, you need a door that's wider than 48" so that the gap is covered. The air gap around the door will allow noise to come in.

with the time involved with glueing up 4 12" panels buying 2 24" hollow core doors is cheaper. I've seen dual doors but never one large 48" door, that will be interesting.

If you are set on making the 4 panels into one, bonding them all together with a solid piece of wood on top and bottom while glueing each door to the other, would be the way I may tackle it.

Advertisement

AustinDB is offline  


Thread Tools Search this Thread
Search this Thread:

Advanced Search
Display Modes Rate This Thread
Rate This Thread:

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off


Similar Threads
Thread Thread Starter Forum Replies Last Post
Therma-tru French doors SUCK! Help!! 01chevduramax Windows, Siding and Doors 5 12-30-2013 06:37 PM
Mortar in Fireplace doors 6stringmason Masonry 8 07-12-2012 08:23 PM
Solid core flush maple doors Trim40 Finish Carpentry 11 03-08-2010 03:43 PM

Join Now... It's Fast and FREE!

I am a professional contractor
I am a DIY Homeowner
Drywall Talk is for
PROFESSIONAL CONTRACTORS ONLY!

At DrywallTalk.com we cater exlusivly to professional contractors who make their living as a contractor. Knowing that many homeowners and DIYers are looking for a community to call home, we've created www.DIYChatroom.com DIY Chatroom is full of helpful advices and perfect for DIY homeowners.

Redirecing in 10 seconds
No Thanks
terms of service

Already Have an Account?