Originally Posted by keekers
Sue and Henry,
How did you get the aluminum inserts between the fiberglass layers? On the UHaul
there are only about 1 inch entry points capped with plastic inserts. Not much room for tools, hands or anything else. Any pictures?
On the frame, I cut the upper hinge support through the inside wall. The lower one is out of sight since it is in the bench box. So this shot is from the inside of the burro
showing the upper hinge support. When it was in place, instead of classing it in, I covered it with a linoleum print cut so it is still accessible if I need to get in.
I used thinner aluminum on that because it could be bolted (the actual door I used screws rather than bolts). The sheet was probably only 8 or 6 gauge.
The door itself needed thicker support so this aluminum was very thick. We cut into the door side at the the hinge to minimize damage and slid the cut slab in the space. We sized it pretty snug and after securing it in place, we drilled through the door where the hinge screws were to be located then used a threader to make the spots for screws. We could have just bolted through the door instead, but I didn't want bolts inside the door and I didn't want to bury the bolts under fiberglass in case it needed removal at some point.
Hope that helps - please ask if you have more questions. My door was a mess and needed quite a bit of work.