My next little project was more of an experiment. Everyone uses sand for density on their stages. Well I thought: I have a sealed hollow core door, how about using sand in that? Here are the results:
One hollow core door.
First off is to seal up any holes like the one were the door knob hole was drilled off position.
I filled it with expanding foam, clamped it up while it expanded, and poof! no more hole.
Don't forget to check the BOTTOM of the door too for holes like this one.
Next I drilled 3 holes in the top of the door to pour the sand into.
I positioned the door so it would not side around while I filled it.
And then I filled it full of sand. DON'T use this sand. It has too many rocks in it.
It took about 2 hours to fill it up. Mostly it was fighting the rocks that kept clogging up the funnel. After it was full I plugged the holes with foam.
The cute little screws that held the hinges up before are replaces with something a bit more substantial.
I also added a few more hinges since the door weighs about 125 lbs now.
And there we have it.