Need door rebuild instructions

[Gone Kayaking]

Hi
I had hoped to allow some nice vintage trailer restoration professional to take on the rebuilding of my door and cargo hatches but sadly, find myself again low on funds, and in the diy mode. I've searched the door forum and couldn't find a post that really does the start to finish.

I'm not sure why taking the door off and rebuilding it intimidates me more than everything else I've done, but for some reason it does.

So if anyone has instructions....from removing the piano hinge to the finishing touch of adding the bargman lock back on please reply or point me to a thread. I'd be quite grateful.

[dawgpound]

I have this rebuild album of the 1970 Starflyte door that I created. It may or may not be helpful.

vintageshasta.proboards.com/index.cgi?board=doors&action=display&thread=4785

[Gone Kayaking]

Thanks Ross....this is really helpful, as I'm definitely going to need to make some of the metal repairs as shown. I still feel a bit over my head on it though. This is my post fourth of July project when the trailer will have some down time.

[thezavalas]

We took our door off the piano hinge pretty easily. The p/o had mutilated it so we needed to re-build it. We took the skins off and cleaned up the wood frame. We took the skins and frame to a sheet metal shop and he gave us all new pieces to put the door back together with. We are not handy people, nor are we at all familiar with Shasta restoration, this is our first time around. But the door was not as hard as we thought and it looks great. Pittsburgh lock and all! We spent $50 on the aluminum and no labor because we put it together ourselves. Try looking for a sheet metal place in your area. If you tell them over the phone, they usually have no idea but if you show them what you need they can probably help you.

[tylerbes]

Kayak... its really not that bad but keep in mind the door is alomst entirely held together with nails. Take lots of pictures. You will have to get the door down and remove all of the nails that hold the aluminum to the frame... set it all aside. Then you need to rebuild the wood of the door. Use whatever is left as a template...its very basic inside. If you have simple wood working skils and tools, you can do it. Then reskin the wood on the inside of the door, 1/8 birch plywood if you can get it. You can use 1/4 but you will need to make the frame thinner to compensate for the thicker plywood. Use the little brass nails with round heads. Cut the door hnadle hole and varnish the wood inside of the door . So now you have a door frame with one side skinned with wood and finished.

Then you need to bang out any dents or bends in your aluminum.... be careful I like to tap on a block of wood on the aluminum instead of hitting it directly. Once happy put your skin and frame back on with nails as it was before... paint (if you want)... door handle back on... rehang, and Bob's you Uncle.

My door was in really bad shape and I got it looking pretty good. Just takes time and patience... and a good hammer.

Ok maybe it is alot of work But it can be done in a weekend.

Good luck

[Gone Kayaking]

Great thanks all, I think I am now set. sorry for being so tardy in posting back, the door may be a mess but I can still use it when I go camping.

Love that saying Bob's your uncle.