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So I'm finally to the point of finishing out our house and am wanting to use interior doors of an atypical design in terms of panel layout and proportion. I also would love to have 1 3/4" doors, but funds are very limited. I know that TruStile has been making MDF doors for years, so why couldn't I? I'm a seasoned renovation contractor who's a finish carpenter at heart, so I'm confident in my skills. I'll be building the entire kitchen and numerous built-ins. My latest idea for these interior doors is to build frame and flat panel using a sheet of 1/4" MDF cut to size (say, 32" x 84") as the core, and then laminating strips of 3/4" MDF onto both faces in a frame and panel configuration. I'd also machine both edges and glue in a solid strip of poplar, like TruStile does. I could machine the inside edges of the frame members to make them look like cope and stick joints, or I could leave them square and apply a bolection moulding. It seems like I'd end up with flat, stable, custom doors at an affordable price. I should mention that part of what has spurred this train of thought is my need for some custom height doors in the upstairs bedrooms and the exorbitant cost of having those made (not that I wouldn't charge at least as much, but we're broke right now).
At any rate, any insight would be great. I don't want to be short-sighted in doing this in terms of durability, especially with three young daughters in the house. Would they clobber these things?