[Shop-talk] Odd-shaped door?

[Brian Kemp]

Doug - If you don't need to actually regularly use it as a door, how 
about just trimming down a sheet of 4x8 foam insulation board to be a 
pressure fit in the opening?  See 416989 or 270895 at homedepot.com for 
an example.  It can sit there most of the time and when you need to use 
the door, just pop it out.  If paintable, put a coat of paint on it and 
it can look just like the wall.  If you want to make it a bit more 
durable, put a shallow channel on the bottom and a deep one on the top 
so you have it held more securely, but then just lift it out like you 
might remove a sliding window or patio door.

In my case, I will probably use Peter's reply at my house with a thin 
sheet of exterior grade plywood (coastal California, exposed to the 
weather).  I have an access door to under the house that is 2' wide by 
4' tall, also an expensive custom size.  The existing door is an 
interior hollow core door slab, poorly cut down, that was laying in the 
dirt when we moved in.  About a dozen screws have it sort of working, 
but a new door is needed.  If you go this route, I second the 
recommendation for two doors, 3' for most of the time and a 1' door or 
panel you can remove when you need the full width.

Brian

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
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