Door

[Sunliner92]

When I purchased my Sunline 1984 T-2100 the door basically fell off and I need to replace it. What are my best options, are there replacements for this and additionally could I build one myself to replace it worst case. Does anyone know the dimensions the door would need to be if I cut out a new one from wood?

Thanks,

Casey

[Sunline Fan]

Hey Casey,

The original door was basically a wood frame, filled with styrofoam in the middle, and sandwiched by two pieces of fiberglass reinforced plastic (FRP) panel glued to it all. Then there was aluminum trim all around the edge.

If you have all of the aluminum trim, I think it's easiest to build a new one, especially if you have some construction confidence. If your FRP panel is still good, you can reuse it, but new is available at Home Depot in a 4x8 sheet. Many times water will sneak down between the bubbles of the FRP panel and the aluminum trim on the bottom of the door (it was never sealed from the factory), making the wood wet, and causing it to rot. It's only a matter of time before the whole door bottom is rotted away and no longer structurally sound, aka ready to fall off.

If you can find a replacement door, it will likely be very expensive and special order. Most RVs produced in the last 20 years have radius top corner doors, so a surplus door won't fit.

Do you still have your four aluminum edge trim pieces? Lay them out on a table and take a measurement from inside the channel.

[Sunliner92]

The metal frame is still good and the hinge side is still connected very strongly but the entirety of the rest is done for. The window is still good, the trim, doorknob and locks but the main body would need replacing. What all should I buy for the main body? Foam? Wood? Or is it just foam I need and sandwich it between? Any ideas of dimensions for the 1984 T-2100 too for the Piece I would need. I assume foam wouldn’t be all as unsure how the lock would hold.

[Sunline Fan]

I would buy wood and stryofoam insulation. You may need to trim down a standard size board to fit the opening in the trim, once two layers of FRP panel are added. Just build like a big picture frame, add a brace in the middle and box for the handle to mount, and fill the rest with the styrofoam.

I'm not sure of dimensions. I would measure your existing door and build the new one to the same size. The wood frame overall dimensions should be the same size as the old plastic panel, as a reference.

[Sunliner92]

Great thanks! Would the brace need to be vertical or horizontal? And what’s the best way to install the locks and doorknob once that’s built? Do they have Styrofoam insulation at Home Depot is it the same as foam board?

[Sunline Fan]

I wouldn't say the wood seals the styrofoam, it's more the styrofoam fills the gaps between the wood.

Here's a video that shows how the door is constructed and how to repair:

[Sunliner92]

Great thanks for all the help I feel much better about it then I did before. Actually much easier then my original replacement plan we were about to trim down a house door and try to install it to the frame and weatherproof it for replacement but this seems much better then that haha.The video will help as well i appreciate it the door is number one priority right now. Where can I get the foam insulation?

[JohnB]

Casey,

This link may help, it has some pics of a door rebuild.
https://www.sunlineclub.com/forums/f...ild-14425.html

As to where to get the foam insulation, I would recommend closed cell insulation board. Water does not affect this like open cell foam board does. It does cost a little more, but it is worth it in my view. The white Styrofoam board used in the doors Sunline used/bought originally, sure look's like open cell foam board.

Here is closed cell made by Owens Corning, Foamular. They have different sizes, I think yours might be 1 1/2" thick.
https://www.homedepot.com/p/Owens-Co...88WD/202085958

Hope this helps

John