Built a nice solid custom door thanks to some help and design from GetGray. Measured sound at the door with it open at 100db and closed at ~60db. Measured with an Android app on my phone, so I am sure its not 100% exact but close enough.
Poplar frame with 1x4's
3/4" MDF for front and back
Three 1/2" layers of drywall inside with Green Glue between
And sweet massive custom hinges.
Zero international seals.
Since this door isn't really very pretty, instead of trying trim to spruce it up, I am thinking of painting the exterior silver metallic and trying to make something on the door face that looks like a vault wheel and call this theater "The Vault".Edited by hifiaudio2 - 12/3/12 at 2:28pm