I have used the HDF like Jim McGrew suggested, It works great. HD and Lowes typically don't carry that so I buy from lumber supplier and ask for "Plum Creek".
1. door grade mdf comes in a couple of forms
a. syp fiber with extra resin
b. "plum creek" is simply standard grade without the extra resin but made
spruce pine or fir fiber so it is softer and doesn't fuzz as much
Both of these options should be about the same price and will be available through wholesalers who service the cabinet industry.
2. HDM high density machine grade Plum creek fiber with extra resin and higher pressure, therefore extra density.
the second is the highest cost alternative but just about takes sanding out of the picture.
Look for double refined (Trupan is the manufacturer) or super refined (can't remember manufacturer name...something "Green"...we get it from Fessenden Hall in PA) MDF. Another good option if you can get it is Medex, which is water resistant MDF and is solid all the way through. I've heard their non-water resistant version is call Medite and also works well.
I've used all of these to make MDF doors and my favorites are Medex and the super-refined stuff. Neither fuzzes up nearly as badly as the box store junk.
This is what Michael Tyley uses in his Vectric free projects.
3M Radial Bristle Discs from mcmaster.com, amazon.com
and http://www.ottofrei.com/3M-3-4-Radial-Bristle-Discs
(stack 3 discs at a time on your rotary tool mandrel)
80-grit (yellow) is what I use exclusively, but other grits are available
NOTE: grits finer than 220 are not recommended for wood
This is what Michael Tyley uses in his Vectric free projects.
3M Radial Bristle Discs from mcmaster.com, amazon.com
and http://www.ottofrei.com/3M-3-4-Radial-Bristle-Discs
(stack 3 discs at a time on your rotary tool mandrel)
80-grit (yellow) is what I use exclusively, but other grits are available
NOTE: grits finer than 220 are not recommended for wood
I've managed to get good results by doing the following:
Coat the MDF with sanding sealer to start with. Sand it, carve it, one more coat of sanding sealer. There won't be a ton of sanding needed typically after that, just a 320 grit sanding sponge and paint sticks well.
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