Should have something between the two layers of the FG door

[HawkBoler72]

Hi, somewhere I noticed someone said there is wood between the two layers of the fiberglass door. I found nothing inside mine,and wonder if I should put something inside to connect the two layers.
Thank you in advance for any comments/suggestions.

[Johnny M]

My 71 Boler door was original and had wood slats inside which had turned to a mushy pulp from years of water leakage in around the window. It was also very heavy from being water logged and a PO's weep hole at the bottom didn't do much good. I removed all the pulp and replaced it with 1" styrofoam insulation cut to fit (much lighter now) Another factory could have used something different inside or perhaps nothing at all, but with yours only a year older than mine, a PO could have rebuilt it and left an empty void. I also added a hand bend metal tube frame epoxied to the inside of the outer layer of fiberglass to help retain its curved shape. In hindsight, the only thing I can suggest that I would do different is to take more time to preserve the inner fiberglass skin by trying to separate the two layers as opposed to cutting it apart, I ended up remaking an inner skin using the outside as a mold covered in wax paper.

[HawkBoler72]

I filled in some Window & Door Insulating Foam, as shown in the attached picture.

[steve dunham]

Originally Posted by HawkBoler72

I filled in some Window & Door Insulating Foam, as shown in the attached picture.

I used the same foam to fix the door on a small refrigerator .
Has held up for about 10 years. You want the foam shown in the picture , not the triple expanding foam and don't expect to get the door apart after the foam dries

[Sohkraites]

The process you used was very similar to what we did... Our door was full of rotten mush...We scraped it out and replaced it with a metal tube frame filled with foam insulation except for where the lock was. The final inside cover was simply cardboard which we then fiberglassed over. Works great for us!