[Top] [All Lists]

Re: [Shop-talk] Odd-shaped door?

To: Doug Braun <>
Subject: Re: [Shop-talk] Odd-shaped door?
From: "Peter J. Thomas" <>
Date: Thu, 14 Jan 2010 16:08:14 -0500
On 1/14/2010 8:58 AM, Doug Braun wrote:
> Hello,
> My basement (pretty conventional 70's construction) has a set of steps going 
>out to the back yard, which are topped with a set of "Bilco" steel doors.  
>They keep the rain out just fine, but they are pretty drafty and chilly in the 
>winter.  I was thinking of installing an insulated door at the bottom of the 
>steps.  The problem is that there is no built-in door frame, and the opening 
>is about 4 feet wide by 7 feet high, and I have never seen doors of this shape 
>being sold.
> Has anybody ever seen a pre-built (or made-to-order) door that would be 
>suitable?  Or would have to build the door frame and the door itself from 
>scratch?  Looks, security, and weather resistance are not important, just 
>sealing and insulating ability.
> I guess I could build up something from lumber and plywood, but I am worried 
>that it wold take a couple of iterations to get something that works 
>reasonably well, is mechanically sound, and doesn't scream "Home Depot weekend 
> Thanks,
> Doug
You can make a door fairly easily yourself using construction lumber, 
two sheets of 1/4 luan plywood and some rigid foam.  Cut the two sheets 
of luan to the size of the door you want.   Lay one sheet down on a flat 
surface.  Gut and glue lumber to go around the perimeter.  Infill with 
rigid foam, and finally glue the second sheet of luan on.   This is a 
stress skin panel door and is the same construction as flat 1970's 
interior hollow core doors except instead of being filled with 
corrugated cardboard you're using ridge foam.

Peter Thomas
Support Team.Net

Suggested annual donation $12.96

Shop-talk mailing list

<Prev in Thread] Current Thread [Next in Thread>