Trillium Door repair on frame

[Island Claire]

Last summer we redid the support system for the door on our 4500. Next summer I hope to do the door its self, as last summer we had to bolt through it to keep it on.



First I peeled back the ensolite and then cut two openings in the wall where the hinges are.

Then I removed the back of each hinge pocket to get at the rotten and well drilled wood, and removed it.
We filled the holes on the outside shell with JB Weld.

We cut and filed to shape, two pieces of mahogany that we then fiberglassed back into the pocket.
We bought a piece of flat aluminum that runs between the top and bottom holes. We re-drilled the holes on the outside going all the way through into the metal.
Then we fiberglassed the holes on the inside and reattached the ensolite.
Now I want to take the top off the pocket on the door part of the hinge and replace the wood inside there as I know it is very rotten.

I hope that the pictures help.

[Jim Bennett]

Originally Posted by Island Claire

Last summer we redid the support system for the door on our 4500. Next summer I hope to do the door its self, as last summer we had to bolt through it to keep it on.



First I peeled back the ensolite and then cut two openings in the wall where the hinges are.

Then I removed the back of each hinge pocket to get at the rotten and well drilled wood, and removed it.
We filled the holes on the outside shell with JB Weld.

We cut and filed to shape, two pieces of mahogany that we then fiberglassed back into the pocket.
We bought a piece of flat aluminum that runs between the top and bottom holes. We re-drilled the holes on the outside going all the way through into the metal.
Then we fiberglassed the holes on the inside and reattached the ensolite.
Now I want to take the top off the pocket on the door part of the hinge and replace the wood inside there as I know it is very rotten.

I hope that the pictures help.

9?m

[David Tilston]

Clair, I am a bit confused by the metal plate. Is it behind the wood you put in? Do the screws go in the hinge through the fibreglass shell, wood, then the plate? I have had a simmilar idea, but with a stainless plate, with stainless nuts welded to it.

ON EDIT: Jim, What are you trying to say?

[Island Claire]

Yes, the screws go through the shell, through the wood and then through the plate. We thought about bolts, but did not want to have an access panel in the wall in case the bolts came lose, or we had to remove the door hinges again.


It was tricky to get in. It is based on the boler idea. They have a 1 inch metal tube that runs beside the door that their door screws into.

[ckayaker]

Following...

[clyle]

Island Claire. Thanks so much for this post. I have been needing to do this to my Trillium for some time now, but lacked the nerve. Your post was great. You must have been desperate yourself and/or have a lot of nerve and talent.

[Trill136]

Very nice repair.

An excellent way to approach and awkward situation.

The door on my Trill, didn't have the original hinges at all.
They had been replaced by some "T" strap hinges purchased at the local lumberyard.

The door was toast.

[David Tilston]

Originally Posted by Min

Very nice repair.

An excellent way to approach and awkward situation.

The door on my Trill, didn't have the original hinges at all.
They had been replaced by some "T" strap hinges purchased at the local lumberyard.

The door was toast.

If you are ever in Calgary, I have a spare door.

[Trill136]

Thanks for the offer Dave.

I have managed to create an acceptable alternative.