Help with rotten Boler door

[LindaR]

Hi, we just bought a boler to fix up (after being inspired by this forum). Didn't even know what a Boler was in the spring!

Anyway just looking for ideas. Started with our door bowing out at the bottom. We bought rods to bring it in like the guy did with the Tank. I then noticed, when I took off the door handle to clean, that the wood was completely soaked and rotten. We cut off the inside layer of fibreglass and all the wood inside the door fell out in a rotten heap along with some water! (brought the door in a few inches at least). We were going to put wood back in the door and had a strip in the bottom but when we went out this morning both edges inside were wet and so was the new piece of wood. We took off the window frame inside and the area around window is dry so we have no iea where the water is coming in.
We were thinking of putting in the pink styrofaom insulation between the fibreglass- in case it leaks again. We think the bolts that have to go through the door to hold the rods will be ok as the fibreglass shell will still be there on either side of the styrofaom. Any thoughts?
We also have new hinges to put in but will have to make new holes as they don't fully align and the old holes aren't snug anymore. We were going to patch the holes with Bondo-Glass, will that work to re-drill the holes through?

tried to post a pic but it didn't show up on the preview.

[LindaR]

here's the door- guess my first try the pic was too big

[Alf S.]

Hi: I just re hung the door on our Boler and I used Tech Steel to fill the holes...wks like a charm. I bought it at a local auto parts store. It's just like plastiseen only it is an epoxy that you blend by kneeding it then press it into the holes let it set up for 1 hr. and file smooth and re drill. You can buy square tube aluminium @ Princess Auto to replace the wood inside the door.
Alf S. North shore of Lake Erie

[Donna D.]

A familiar problem. Here's a good posting for you to look at:
1972 Boler Door