[Shop-talk] Odd-shaped door?

[Peter J. Thomas]

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 project"...
>
> 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