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Old 11-29-2010, 02:13 PM   #1
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Entry door flew open while going down highway

The doors internal frame broke on both sides. Can this be repaired or will I have to find a donor trailer to fix this?
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Old 11-29-2010, 03:04 PM   #2
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I had this happen many years ago on a 1969 International. I was fortunate to know a very good welder who was good with aluminum. If you find someone like that be sure he is very careful to get the proper curve in the frame. once welded I pop riveted the skin back on and never had a problem. The guys on this site know how to use the right rivets so follow their advice and it will be better.

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Old 11-29-2010, 06:14 PM   #3
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Get a good welder and next time use a wooden wedge in the grab handle to keep the door shut. We have a dead bolt but I don't even trust that.

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Old 11-29-2010, 07:35 PM   #4
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Here we keep on going again......

Neil
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Old 11-29-2010, 10:15 PM   #5
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I had the same thing with a 65. Drilled off the inner panel, then cut two pieces of wood to match the frame curve and clamped them on to hold the shape. Took the door to a welder, good with aluminum, he tacked the break, then I drilled off the outer panel at his shop and he then welded the complete break. It was as good as new when riveted back together. Cost $60
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Old 11-29-2010, 11:02 PM   #6
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Same thing happened to our Caravel. It was my fault, as I neglected to use the dead bolt. There were two brakes, one just above the latch, the other just above the hinge.
I removed the inner skin and towed to a very good welder friend. Then I removed the door. We placed the door on the welding table and supported the top and bottom on 4x4 blocks. This closed the two brakes and caused the door to go back to it's original shape. This will only work if the frame is just broken, not bent. This can be determined by closing the broken door and pushing the top and bottom of the door at the same time to see that it still fits. Very easy after the inner skin has been removed. He welded a bead on the inside and outside of each brake, then ground down the outside beads to a nice finish in the visible areas. He then used some 1/4" thick aluminum to weld support gussets along the where the brakes were and one more at the bottom of the hinge area making the frame stronger than original. I towed back home and replaced the inner skin.

No problem since.
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Old 11-30-2010, 12:15 AM   #7
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Fresh Air

I like your "door lock" design. I think that I will copy it for my 66 TW.

Thanks for the photo, Dan
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Old 11-30-2010, 04:44 AM   #8
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Quote:
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Here we keep on going again......

Neil
Oooh nice!

Ought to market that

Mine is a bit more....rustic.

Aaron
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Old 11-30-2010, 07:10 AM   #9
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Same happened on my 66 tradewind due to dead bolt lock failure on our first 10 day trip on the first day. The door was the correct shape, but inside out. Removed the interior skin and located a heliarc welder. They welded the frame and I reattached the skin. Traveled for 9 more years before selling with no more incidents. I did take out the deadbolt and pinned it so it would never let loose again!
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Old 11-30-2010, 09:55 AM   #10
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Fresh Air

I like your "door lock" design. I think that I will copy it for my 66 TW.

Thanks for the photo, Dan
PM me with your email address and I will send you a template.
Neil.
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Old 12-08-2010, 06:52 PM   #11
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So if the inner skin is removed the door can be welded while still attached?
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Old 12-08-2010, 07:56 PM   #12
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Outside door lock design...

Quote:
Originally Posted by FreshAir View Post
Here we keep on going again......

Neil
Someone on the Forum made one with a rubber door stop & a tent tie bungee (has a plastic ball on the end). We used that idea and it works great. Sorry about your door!
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Old 12-09-2010, 07:35 AM   #13
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Boondocker, When the welding was done, the door was still on the hinges. In fact it made it easier to fit the contor of the opening with a couple of adjustments of the weld,
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Old 12-18-2010, 08:38 PM   #14
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Here is my idea. works for me!
When getting ready to hit the road.
1. Store Steps
2. Secure the door
3. Raise the stabilizers
4. Disconnect power, water, TV, sewer, if applicable
5. Hook up TV, hitch; breakaway switch; UCord; safety chains
6. Raise tongue jack
7. Check all lights; tires and brakes.
If I don't do the steps and door first, I'll probably forget them.
I made a check off list, kind of like pilots do when getting ready to take off.
If I don't check it off. I'll forget it and that's not good.

It's still beyond me why after all of these years AS has not reversed the door.
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