XenaCommanders Place

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Truck Blog

Door Construction Oct 2015

Posted by XenaCommander on October 13, 2015 at 3:45 AM

Never having constructed a door before I had to give it some thought..   I could of course go to a door manufacturer and buy one off the shelf but the size for a stand  house door would not suit the truck..  So I thought I would have a go at building one.  
A simple frame with an inset of ply would be light and rigid...  I mocked up a practice one...

Hmm...  it should work in principal..  now I just need to upsize it.   The hardest part was to get straight timber again so off to ITM again and got some 4x2 and milled it down to 20mm..  and cut it the size I wanted...

It seems the only way to get straight timber is to mill it myself... 

The main door cut to size...  with the frame done I figured it will need some cross bracing to keep it reasonably rigid..    So I added 3 cross braces..   Using the Festool Domino system made things easy to get tight and secure.

Time for a dry fit...   It is slightly oversize..  which was planned... once it is finished I will cut to exact finish size.  Now to rebate the insets for the ply...    I love using a router now...

All rebated...  Now the messy job of glueing it together...   Once it was glued..  I cut out the extension door..

Extension cut and dry fit..  Tomorrow I will rebate and glue it up before heading north again...  Work is calling.
Mumble...    I need to buy some piano hinges...

A week or so later...

Back from trip to Gympie in QLD...  Time to continue with doors... this next bit was tricky...  I had to cut the ply exactly to size to fit in the rebate..  easy to say..  not so easy to do... but I cut the sheet slightly oversize then fit then trim..  then fit..  then trim.. then fit...  then trim.. until it fit..  of course nothing is exactly square even though it was intended to be... but Murphy doesn't allow exact right angles..!!!

Hey presto...!   They look pretty good...  a very slight bow is appearing in the large door but that will be easy to remove once I hinge them together...  ( I hope....!)

I still have to get piano hinges...  I am off to Taupo on Friday so will hopefully pick them up there...
In the mean time I am lining the frames around the fridge space with ply before installing the fridge for final time.

Very fiddly but looks better with them on... I have decided to line the outer wall of the fridge space and the ceiling..  I will leave the wall of the shower just in case I have plumbing issues...   I will panel the other side in the cupboard space and make a removable panel so I can get to the back of the fridge.

Stay tuned...

Categories: Motorhome Building

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