Alley-Kat
Elder Statesman
Hollow core, no panel (smooth or flat surface) door blank (no hinge, door handle or striker cut outs), put on a Formica top.
Hollow core doors are very strong and flat, yet light weight.
Maybe do all sides (edges), top and back in Formica (sort of water proof, if it's always going to be outside). Formica is easy to apply with contact cement. Need a router to really make the Formica edges look nice, but a cheaper solution is to cut the Formica close (after gluing it down, do the edges first, then the top or back) and then file the Formica edges smooth.
Smallest door blank I've seen is 24" x 80" at places like Home Depot and Lowe's. If you have to cut it to size (by a fair amount), then you may need to trim the honey comb insides just a bit where you cut the door and insert (glue & clamp) a new light weight wood edge to make it look "finished" and reseal the door where it was cut.
That's the best explanation I can give. If you're confused and still interested, ask specific questions if you need to and I'll try to answer.
Hollow core doors are very strong and flat, yet light weight.
Maybe do all sides (edges), top and back in Formica (sort of water proof, if it's always going to be outside). Formica is easy to apply with contact cement. Need a router to really make the Formica edges look nice, but a cheaper solution is to cut the Formica close (after gluing it down, do the edges first, then the top or back) and then file the Formica edges smooth.
Smallest door blank I've seen is 24" x 80" at places like Home Depot and Lowe's. If you have to cut it to size (by a fair amount), then you may need to trim the honey comb insides just a bit where you cut the door and insert (glue & clamp) a new light weight wood edge to make it look "finished" and reseal the door where it was cut.
That's the best explanation I can give. If you're confused and still interested, ask specific questions if you need to and I'll try to answer.