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Old 05-26-2011, 05:10 AM   #1
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Door repair on our Sunspot

The bottom aluminum rail of our door on Spot was coming undone, making it hard to close the door, plus there are a few holes in the door that need to be fixed. I can disassemble the door and rebuild the interior wood frame, plus maybe add some strengthener (i.e., hard blue insulation foam?), but how would you suggest I repair these holes in the door, and screw-holes in the trailer side by this "door hole maker?"

Thanks for any help! This is a project for the weekend.

Frank
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File Type: jpg 3.jpg (43.9 KB, 4 views)
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Old 05-26-2011, 06:18 AM   #2
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More pics - rotted wood!

Gotta run to work, but here's some more pics. I think I got a handle on this baby...

Frank
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Old 05-26-2011, 08:37 AM   #3
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Looks pretty cut and dried. Remove deadwood, remove corrigated paper, install new wood, replace paper with proper thickness foamboard, watertight seal and zip it up.

jim
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Old 05-26-2011, 08:57 AM   #4
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Yep, I hear ya Jim! Working at it tonight. Just bought some poplar that should more than fix me up with minimal tinkering.

Frank
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Old 05-26-2011, 09:16 AM   #5
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I think just making sure seams are tight and materials waterproofed as much as possible will make the door last longer than the rest of the camper, LOL!

Someone here did a door rebuild but I can't find the link right now. They removed the door, took it apart, replaced wood with treated (I think) and used foam insulating board for the guts. I bet it was a much better door after the rebuild. My main concern would be waterproofing and protecting seams against future leaks.

Good luck with it.

jim
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Old 05-26-2011, 09:23 AM   #6
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I would love to see that link Jim. Too busy to look for it though. I'm using poplar for a reason - it is good at repelling water. Pressure treated stuff had a lot of water in it when you buy it. I would never use it someplace sealed up where you don't want moisture. Trust me, I been rebuilding boats for years. I've used poplar before for transom rebuilds in aluminum boats, lasts a long, long time!

I couldn't find foam that was the right thickness, so (for now) am considering gluing together good heavy duty cardboard for the few areas on my tiny 4' door that need it.

Need to figure out how to repair the holes in that vinyl exterior door panel. Couldn't find anything at Lowes or the local hardware store. May stop at the Boat n RV Warehouse on the way home, see what they have. Failing that, it's gonna be Gorilla tape for now, and maybe a piece of sheet aluminum in the future!

Frank
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Old 05-26-2011, 09:36 AM   #7
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Frank, Try this link http://www.sunlineclub.com/forums/me...icture640.html


Edited to ask: Is the outside vynl or fiberglass? I know there is age difference but mine is fiberglass, I think.

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Old 05-26-2011, 09:41 AM   #8
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I was thinking of doing that too Jim, but for now am gonna cheap it out with cardboard. This door is so simply constructed it would not be hard to re-do it sometime in the future when I have more cash. Right now we're fixing this up on a budget! I really would like to replace the vinyl with aluminum anyways. The Sunline tape on the door is the worst tape on the trailer, and I assume it is no longer available?

Frank

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Old 05-26-2011, 09:53 AM   #9
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for a budget fix the cardboard will do and it is a small area. No problemo!

jim

naptime for an oldman.
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Old 05-26-2011, 08:24 PM   #10
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Quote:
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Frank, Try this link http://www.sunlineclub.com/forums/me...icture640.html


Edited to ask: Is the outside vynl or fiberglass? I know there is age difference but mine is fiberglass, I think.

jim
It's plastic. Now it's known as FRP panel...you can buy a 4x8' sheet of it at Home Depot or Lowes. I think it can be bought in other colors, but the big box stores only stock bright polar white. It's a popular finish for car washes, showers, and commercial kitchens where stainless steel isn't desired.
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Old 05-26-2011, 08:26 PM   #11
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I was thinking of doing that too Jim, but for now am gonna cheap it out with cardboard. This door is so simply constructed it would not be hard to re-do it sometime in the future when I have more cash. Right now we're fixing this up on a budget! I really would like to replace the vinyl with aluminum anyways. The Sunline tape on the door is the worst tape on the trailer, and I assume it is no longer available?

Frank
Correct, it's no longer available. The door tape typically falls apart first due to the rough texture and the tape not sticking to it very well. Water gets behind and it starts peeling.
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2007 T-286SR Cherry/Granola, #6236, original owner, current mileage: 9467.8 (as of 5/26/19)
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Past Sunlines: '97 T-2653 #5089, '94 T-2251, '86 T-1550, '94 T-2363, '98 T-270SR
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Old 05-26-2011, 08:31 PM   #12
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Right. 33 bucks for a 4X8 sheet at Lowes. I didn't think the tape would still be available, but thanks for confirming that for me. I may just patch this plastic for now. It's a budget thing. Got 4 scissor jacks in today, couple levels and a hitch aligner. More weekend stuff, along with getting the newly painted classic speed boat rigged. Plenty to do!

Tell me, any idea if I can use fiberglass to repair that FRP? I'm good with fiberglass and have resin, cloth and matt in my shop.

Frank
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Old 05-26-2011, 08:57 PM   #13
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Right. 33 bucks for a 4X8 sheet at Lowes. I didn't think the tape would still be available, but thanks for confirming that for me. I may just patch this plastic for now. It's a budget thing. Got 4 scissor jacks in today, couple levels and a hitch aligner. More weekend stuff, along with getting the newly painted classic speed boat rigged. Plenty to do!

Tell me, any idea if I can use fiberglass to repair that FRP? I'm good with fiberglass and have resin, cloth and matt in my shop.

Frank
The good news is, keep the old door skin and it would be easy to have striping made. They are four individual colors, non-printed (solid color vinyl), and no fancy cuts.
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1997 T-2653 Blue Denim, #5471
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Past Sunlines: '97 T-2653 #5089, '94 T-2251, '86 T-1550, '94 T-2363, '98 T-270SR
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Old 05-26-2011, 09:20 PM   #14
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Tell me, any idea if I can use fiberglass to repair that FRP? I'm good with fiberglass and have resin, cloth and matt in my shop.

Frank
Don't know if this will help but if it is true FRP that is fiberglass reinforced plastic. They add the fiberglass part to make it stronger

Some fast hits on the internet
Fiberglass Reinforced Panels (FRP) from FRPshop.com

FRP Wall Panels: Marlite FRP wall systems decorative sanitary surfaces.

I know the heavy FRP industrial water tanks at work, about 1/2" thick, can be repaired with resin and matt. Don't 100% know about the door panels but odds may be in your favor.

John
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Old 05-27-2011, 03:37 AM   #15
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The good news is, keep the old door skin and it would be easy to have striping made. They are four individual colors, non-printed (solid color vinyl), and no fancy cuts.
Where would I get tape made? One of those vinyl sign shops?

Frank
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