Rebuilding exterior access doors...

[Hueytownalss]

I am starting a thread for rebuilding the access doors on my 1978 Silver Streak. I am sure some of my AS friends have the same problem. Water, over the years, had gotten between the inner and outer layer, and had rotted the inside. The water made them heavy. The doors, I thought, had wood inside them. Instead they actually had some kind of pressed paper, maybe masonite. Either way it had to be rebuilt.
Initially I thought I would take them apart, put in new wood and put them back on. Then I thought I would try something a little different. This is my attempt to use spray "STUFF" foam inside the inner and out panels. This would make them lighter and water would not damage them in the future.
The first picture is the door as it was on the trailer.

[Hueytownalss]

The doors are riveted to the hinge, which is riveted to the trailer. There is a band around the door itself that have a couple of rivets holding it in place around the door skins.

I removed the rivets connecting the door to the hinge but left the hinge on the trailer. Then I removed the rivets holding the band to the skins, and finally removed the band. This is the band removed:

[Hueytownalss]

When I got the band off and took the inner and outer skins apart, this is what I found!! A rotted mess!! Most of it just fell out.

This is what got me to thinking about using spray "STUFF" foam inside instead of wood.

[tschat]

I would not use the spray foam. It does not handle water very well. Also it expands far more than you ever think it might. If you do continue with the spray foam, get the window/door version. It doesn't expand as much. I would recommend "foil bubble wrap". I don't know the official name for it, but it is used as radiant barrier in houses and can be bought at any of the big box home repair stores. If that is too thick, I would get roof sheathing. It looks identical to what you removed.

[Minno]

Reflectix is I think what you're looking for the name of, tschat. Or perhaps you could buy rigid foam insulation and sandwich it between 2 layers of thin aluminum in the door. If you foam it, I agree get the window/door stuff. What you have in the can there, is supposed to expand lots, and will. Yeah, the old stuff kinda looks like Masonite. Doesn't tolerate water well. You probably need to put new seals on those doors so water doesn't get in (probably already thought of that, didn't you!).
Good luck!

Kay

[Hueytownalss]

Now, how do I get spay gooey foamy sticky gunk in side the two panels? Hmmmm!

I needed a form of some sort to hold the pieces in correct alignment and thickness. Remember the skins with the liner have to go back inside the band. The inside of the band was 7/16", and the thickness of the previous "wood" material was 3/16".

First, I cut two pieces of 3/4 plywood, (I just happen to have it already), to the exact side of the panels. Then I glued and nailed plywood cleats, or stops, to one of the panels.

[Hueytownalss]

Tschat and Minno, Oops!!! Already used the foam!!

Water actually got in because of the lock, and the small crack where the band meets. I intend to seal everything with Trempro 635 when i put the band back on.

I thought I would use the swelling of the foam to my advantage. When I got my "contraption" together, the swelling would push the panels apart to the correct thickness. But I'm jumping ahead on my story.......

[Hueytownalss]

Next I cut spacers exactly 3/8" thick. These would be used between the panels to keep them apert the correct thickness. The ouside thickness of the two skins and the spacers came out to exactly 7/16", and will fit back in the band.

The following pictures show the first skins, good side down. Then with the spacers. Then the other panel, good side up. Then the other pece of plywood.

I pressed these pieces tight a screwed the the cleat into the top piece of plywood.

There is info about the lock area, but I will get to that shortly.

[Hueytownalss]

you can see the thickness in this picture.

[Hueytownalss]

Around the lock area, I thought I would "beef" up. The lock has a little screw that attached from the back side of the door. It also went into the wood, before.

I looked for something aluminum as a replacement, and also cheap. I found in my storage, an old threshhold that I could use to "beef" this area up. I will post profile picture of this piece when my phone charges.

The following pictures show the piece cut and in place before the foam goes in.

[Hueytownalss]

I tried it and it worked!!!! BUT DO WEAR GLOVES WHEN USING THE FOAM SPRAY!!!! It is STICKY!!!!

I spayed the foam in from the top. I forgot to take pictures after I spayed foam in the form, because I got some of the STUFF on my hands, and it IS sticky.

After the foam expanded, I took a nap while it cured. A couple hours later I took the door out of the form, and removed the spacers that were on the edges. I then sprayed the gaps where the wood edge spacers were and let that set. the pictures shown are after is is out of the form. Then trimmed up a little.

[Hueytownalss]

The last picture, in last post, shows my supervisor, Max! I run all my projects by him first.

Will put the band back on tomorrow, and polish the door. Polishing the door is in conjuction of another project on my Silver Streak. It is anodized aluminum. I am de-anodizing it so that it will polish. I have that in another thread. It is so HOT here in Alabama, that I can work on the polishing only a few hours a week.

Not sure how to link a thread, but you can find it by searching for Polishing Silver Streak Project.

[Hueytownalss]

This might work:

http://www.airforums.com/forums/f441...ect-78246.html

[overlander64]

Originally Posted by Hueytownalss

The last picture, in last post, shows my supervisor, Max! I run all my projects by him first.

I think that I recognize the look on Max's face . . . . loosely interpreted . . . . You've spent enough time on that project, now it's my turn. Pick me up and give me some attention too,

My toy Chihuahua is often in a similar position only she will start to cry if I ignore her for too long.

Kevin

My two supervisors (Precious Princess and Prince Little Bear):

[Hueytownalss]

Max is sort of a loner. He's not into the attention thing. He's more of a "will work for food" dog!!! He does like to ride on my motorcycle though!!!

[suzukiman]

lol My supervisor can also relate.