So, I've always had a problem with the Hollow Core Door as benchwork, because the average cost of a new door ends up being the same, or possibly more than just buying the lumber to do it from scratch...in fact, if you were to mimic the construction of a HCD 1x2 frame with solid thin ply top and bottom, you could build it for less possibly. And the compromised involved with 2" of HCD you have to try to fish wires through and the inability to use undertable switch machines without difficulty just put me off to the whole thing. However, that was before I started shopping at the Local Habitat for Humanity ReStore. Basically it's a Goodwill for building supplies and the average cost of a full sized HCD? $10 for a good condition door. At $10 you literally cannot build something for less. However, When you go to the ReStore, never forget your tape measure. I bought a HCD there for use on an extension for an HO layout. I was excited, because it was a thinner door and since this was an extension and I didn't need any curves, I preferred thin, I assumed, because it was a door, that it was probably no narrower than 24" When I got home I realized that for various reasons, I had underestimated the amount of length I could provide and so a 7' door was about 6" too long. Cutting an HCD down is not a good idea, so my next thought was: "well, you've got a stack of Free N scale flex, snaptrack and switches. Why not just build a quick and dirty N-scale layout for grins. It won't cost nothing. That's when I measured the door. Thinking I had a bear minimum of 24" to turn around. NOT SO FAST. It's a 19" door. :| So, New plan is, that door gets attached to some shelf brackets and is used as a shelf in another part of the garage. I went and found a shorty crawlspace access door at the Restore for the princely sum of $6 and I'm going to get a standard 26"-30" HCD for the N-scale layout for $10. So I went from $8 spent on an HO layout to $24 spent on an N and HO layout. sigh...
If you watch the big box stores, they will often have a slot at the end of their door rack, where they put damaged (new) doors. I have seen 80" by 30" unfinished doors as low as five bucks. Of course there is significant damage, both sides, but often still very usable.
That is very unreliable though. ReStore is very reliable. Always a great selection always $10 and usually in pretty good condition. Damaged doors is like the Cull lumber bin. You might luck out, you might not.
We used to cut down HCD's all the time. The trick is, how thick is the filler? If a standard 2X, you cut the door off, cut your filler to fit, slather the inside of the skins and abutting fillers with yaller wood glue, push the piece in, clamp using a couple of 2X4's. Now, if they've narrowed up the filler, you need to laminate some plywood to make the proper thickness. Always worked for m. Dave
YUP That's good advice about always taking a tape measure to Habitat ReStore. It's good advice to ALWAYS carry a tape measure any time you are looking for salvage/scrap/FREE materials. I also have a HAMMER, straight/Phillips screwdriver also. You never know when/where you will find something usable at the right (read cheap/FREE) price. No use carrying home something that will be no use because it is to big/small. Been there, done that! Cutting a HCD down is NO problem as ScaleCraft stated. I have cut at least 4 or 5 down for the basement and closets in our house. Just take your time and pay attention to what you are doing.
In addition to my last post. If you are looking for a Hollow Core Door, don't forget CRAIGSLIST. Look in the FREE section and MATERIALS section. Here in the Louisville, KY listings there are 2 for FREE and 4 or more listed in the MATERIALS Section as I post. FREE is a REAL GOOD price in my book.
When I bought the house I'm living in now, I replaced several old interior doors, leaving me with a nice little stash of free benchwork. Corrently, my small HO scale layout uses two 19" doors and a 26x80" door I had to shorten to fit the end wall. The other end is a 1x12" shelf piece. The biggest expense for me was the hardware (screws, shelf brackets, etc) to support the doors to the walls. Granted, my situation was unique, but as Yoho said, you can get cheap HCDs at any builders salvage supply or Habitat for Humanity Re Store.
