Trillium sagging door repair

[clyle]

Touch up paint using some commercial grade paint and adhesive. Not a perfect match, but good enough for this project.

[clyle]

Dry fit of the door.

[clyle]

New holes drilled through trailer-block-alum plate. 4mmx.7 40mm long stainless steel machine screws. Just long enough.
Nylon nuts.

[clyle]

Brutal tape under hinges.

[clyle]

Done. Door swings like a breeze. It will take a few days for the hinges to settle into the brutal tape so I'll need to retighten the nuts a few times before I reglass the cutouts in the inner wall and reattach the ensolite.

[John in Michigan]

Great work Lyle!! Thanks for the detailed explanation and photos.
Wow tedious, but will result in a lasting repair.

[clyle]

Thanks, but what can I do? I'm a label maker short of OCD!

[clyle]

Last of the pics. Glassed a couple of small tabs at the corners to hold the cut-out section of the inner wall as I glassed it in.

[clyle]

1" matting to glass in the inner wall sections. I left an inch or so open for access if that becomes necessary.

[clyle]

One strip was enough. A bit raggety, but all will be hidden behind the ensolite.

[clyle]

Nothing left to do except reattach the ensolite.

[Kommander]

Thanks for the pics and explanations. My door seems solid but gelcoat is wearing off where the bottom of the door must be rubbing. Gap is different at top from bottom.

I like using bolts rather than screws and filling with resin and glass to eliminate any rot happening.

[jen11o]

Thank you very much for the pictures and thorough explanation! My door is still having issues so I'm looking at what needs to happen to do a repair like yours. I imagine I would be a wreck drilling those holes too!!!!

[stude]

If it was me doing the repair by first item would be to check the Chassis and if okay I would remove some of the flooring inside in front of the Door and I would Modernise it by adding a small amount of metal to suppor the floor and frame the door frame to install a much more modern door sort of like my back door at our old house, but this actually better to do on a Boler as it is way more curved.
I know you think I have a screw loose But I just finished helping a fellow fix his log cabin that was built way back in the 1890's we had to remove all the old logs and re-install new logs to fit, hard work that.
Peter

[stude]

I live in Canada just across the border a wee bit and we get maybe 2 days of slightly warmer weather then go back into the Deep Freeze again with torrential Rain, Were glad we live quite high up now, do not have to do all that hard work like Maintenance just sit back and watch the others do the work. The weather people kept tell us it 12*C today but it was more like 8*C.
No I have no idea when that idiot we got back east is going to open the Border but I think sometime in the next 6 months. I think he is waiting to see that the US has around 75% full Filled it self with one solid shot and do not need a 2nd one or you have had your 2nd shot.

Peter