So I have read a bunch of books on door construction and I have finally come up with my own design for a somewhat sound proof door (RwDB=40db).
My idea was to glue a frame of 27mm or 18mm plywood (=VP(blue)) onto a sheet of 18mm VP. The recess in the center would be filled with 27mm/18mm MDF (brown), followed by another layer of 18mm VP. A mitered frame of mdf would then be glued around the edges of the sandwich, which should allow for profiling of the doors edges, without affecting the finish. Sheets of 4mm MDF would then be glued to both sides of the door, so that a smooth finish can be achieved, without any interference by the grain.
Rate this construction and tell me what you would do differently.
What are you talking about? Gaps on soundproof doors are generally closed by 3 layers of seals on the sides and top, while there is also an integrated seal on the bottom of the door, which only lowers to touch the floor if the door is closed.
That stuff about sustaining life is complete bullcrap. Ever heard of diffusion? Unless you are living in an air baloon, then you are right ofc.
Yeah i know about those concepts. Those problems can however be overcome by simply:
A) Increasing the weight of the door (as i have done by using an mdf core)
B)Stuffing the hollow core with rockwool.
What concerns me more is potential warping. There has to be some reason, why almost all modern door constructions, apart from frame and panel doors, are made out of compressed fibre boards (MDF etc.) and not Veneer Plywood.
I made my own doors out of a frame of 2x4s with 1/8" luan glued over them, basically like most pre-hung interior doors are made. No warping issues at all, it's been 6 or 7 years. Picking your lumber very carefully is the key.
>What concerns me more is potential warping. There has to be some reason, why almost all modern door constructions, apart from frame and panel doors, are made out of compressed fibre boards (MDF etc.) and not Veneer Plywood.
Plywood doesn't warp. My guess is MDF is cheaper.