Doors Too Heavy

[NightCap]

I did a search and came up with no suggestions on how to lighten up a very heavy door.
Some if the ideas I have are:
1. I thought I could cut out panels and put in 1/4" ply in the space.
2. I could rout out the excess wood on the back of the doors.
3. Build a door from scratch.

Any Ideas welcome.

[mikeschn]

Build a new door from scratch.

Use narrower ribs inside the door, and use thinner plywood for the skins!

Mike...

[Kody]

It would help if we knew the size of the doors and original thickness. A method you could use is to make a new door from the dense pink foam. The panel could then be covered in 1/8th ply and fiberglassed. A narrow frame can be constructed to mount the hinges and the lock. The foam could be 3/4" thick or even 1/2". The ply skins should be glued on with laminating epoxy and weighted down. This would make a very light door and it would also have fantastic strength and stiffness.
Just a thought,

Kody

[NightCap]

Thanks guys, great ideas. Didn't even think of ridged foam.