Building new door?

[bgeery]

After I had the bottom aluminum sill/frame extrusion stolen, I've convinced myself to have a new one welded out of much stronger 1/8" angle aluminum, as the old one does not seem to have held up well over the years.

Now that I've made the decision to build a custom frame, I also have the opportunity to build a new thicker door as well. I can figure out how to build a basic door frame, and fill it with foam insulation, but does anyone have an idea about how the aluminum door skin is attached and how the door finished?

[Frederick L. Simson]

I can figure out how to build a basic door frame, and fill it with foam insulation, but does anyone have an idea about how the aluminum door skin is attached and how the door finished?

I think most straight RV door frames are custom extrusions that assemble around the inner and outer door skins with some kind of spacer clips between; kind of how a picture frame is assembled. I think most are hollow.