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So the "action" that causes the door to come out of the frame is closing it against the friction. Imagine if the hinge were locked up, and I tried to close it with force. That would pull the door out of the frame. Normal closing of the door, against the friction of the frame, over a period of years, regularly (remember, I'm a full timer), has the same effect.
I think hollowing out the foam core won't be bad. It's styrofoam, so it's soft. I think repeated cycles of moving the threaded rod in and out will give me the pathway I need. I'm not overly concerned with removing too much foam. (Famous last words....)
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