"David Micklem" wrote in message
...
In article , "nightjar"
nightjar@insert my surname here.uk.com wrote:
....
If you are making something as an answer to an allergy, I would avoid
MDF.
There is a slight risk of vapours from the resin causing a reaction in a
sensitive person. My personal choice would be foamed PVC, which is
available
from plastics merchants in 8ft x 4ft sheets, in a variety of thicknesses
and
colours (also thereby avoiding the possibility of paint fumes).
Something
around 10-12mm thick would be lightweight and give you enough to attach
hinges to. It can be worked with hand woodworking tools, but use power
tools
with caution - they can melt rather than cut the plastic.

I'm not familiar with this stuff. How well it take screws/other fixings?

It is similar to a lightweight wood.

I
don't think my niece is sensitive to formaldehyde/urea, just dust, but I
suppose
it can't hurt to be too careful. Isn't the foamed PVC expanded with a
similarly
toxic/sensitising chemical?

I'm not sure what is used. However, it is a closed cell foam, so the foaming
agent stays trapped inside the PVC. I've used the stuff to line medical
clean rooms for years without any problems.

Colin Bignell