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Old 08-24-2012, 07:03 PM   #1
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1977 31' Sovereign
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Is my door doomed?

This is our first AS and I thought of just getting another door and moving on. Then after much reading I'm understanding that new doors are very expensive and each door is a little different. So my question is, is there any saving this door? What would be the best way to repair it?
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Old 08-24-2012, 08:07 PM   #2
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Search the site because there have been a couple threads on door repair
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Old 08-24-2012, 08:25 PM   #3
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You will probably need new skins but I bet you can get the frame back to the right shape with some heat from a torch. Low heat. Don't melt anything.

It will just take time.
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Old 08-24-2012, 08:37 PM   #4
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If the door has an extruded aluminum frame, you can reshape it. I would not use heat. There is a possibility of annealing it. Which will make it really soft and easily bent again. While aluminum has some memory, it is nothing like steel. If you make forms to shape the frame and clamps to move the metal as opposed to hammering it. You will get better results. Take your time and think about the results you want.
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Old 08-24-2012, 09:03 PM   #5
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So what I'm picturing is making a jig that matches the curve of the shell by the door (the curve needs to be slightly more than the shell). Then removing the door and clamping the top first to the jig. (the top doesn't have any damage) Then working the rest of the door into the same shape. By the way the frame is completely broken in two around the deadbolt receiving cup. I'm guessing tig welding will be in order for there. Should I beef up the frame by adding a new piece of aluminum riveted to the inside of the current frame. I'm thinking this would help protect the weakened areas from bending again.

If my logic is flawed please let me know!!
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Old 08-24-2012, 10:14 PM   #6
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Sounds like you are on the right track. If it is possible to have the broken section welded. I would have it welded while it is held in the jig.
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