Replies

1. 
   KiddervilleAcres | Mar 04, 2009 02:37pm | #1

   David,

   A cheap quick and dirty:

   Get some 2" rigid insulation board (4' x 8'), a bundle of strapping, sheet of 1/4" luan and a sheet of 1/2" plywood.   Might want touse 1 2" x 3" for the hinge side.

   Make a 4' x 8' frame with the strapping/2x3 (mebbe add a piece or two inside the frame acrsoo the short dimension for stiffness),  size the foam insulation to fit inside then skin it with the 1/2" plywood and luan and Bob's your uncle.  Sort of like an insulated torsion box if you will.

   Makes for a light fairly strong door and offers some insulation capability as well.

   Regards,

   Bob @ Kidderville Acres

   A Woodworkers mind should be the sharpest tool in the shop!

1. 
   zolton | Mar 04, 2009 03:16pm | #2

   Ditto on this idea Bob. The doors I have hanging on my shed (not my shop), are just pieces of 1/2 inch OSB with 1x4's screwed to it in a classic barn door type configuration. Big exterior hinges, paint, and, as you said, Bob's your uncle...

   ZoltonIf you see a possum running around in here, kill it. It's not a pet. - Jackie Moon

1. 
   habilis | Mar 04, 2009 10:04pm | #3

   I agree, build it. Easy; make it the way you want. Another option is salvage yard. Last time wanted to replace 30" door to basement went to local non-profit building recycling warehouse, got a 42x80" door for 50 bucks cut to height. Only hard part was cutting 1' thick concrete wall, but you won't have that problem. Saw double doors there too.

2. 
   d | Mar 05, 2009 07:07am | #4

   Good ideas - I had checked to local salavage and they had lots of old doors but nothing that was a quick and easy solution.  I had been thinking about the 1/4 ply, rigid foam, frame solution and like the fact that it made sense to you guys as well.

   Thanks,

   David

    

3. 
   pickdesign | Mar 05, 2009 11:11pm | #5

   My shop is 100 year old school house, "a work in progress" the door is at the front section which is uninsulated, but will eventually be an office.  The shop is 22' x 32' and has 10' walls.  I used barn door hardware from Lowes, two sections (behind the white horizontal trim).  Door is pressure treated SYP, 2x6 mortice and tenon, with floating 1/2" cdx, applied plywood design on top with finish nails and applied design was also 1/2" cdx and was stained (5 years ago, and needs to be painted now).  Door is 5' x 8' tall, glass was storm window inset into frame.  Total cost maybe $ 150 mainly hardware.  Barn door hardware will take a good deal of weight and slides easily.  Weatherstripping can be put in between inside of door and wall.  You could make thicker and sandwich insulation as others have suggested. 

   Just make sure the PT SYP sits for a while to acclimate.

   Steve

   
1. 
   marti038 | Mar 06, 2009 12:05am | #6

   Looks like a great place for a shop. You should post some photos of your work in progress as it's coming along.

4. 
   flairwoodworks | Mar 06, 2009 12:45am | #7

   David,

   I built myself a pair of 7' tall x 36" (I think) wide doors for my shop. I used 3/8" plywood skins and grooved the outside face for aesthetics. I put the skins over a 2x4 insulated frame reinforced with diagonal braces. I also added a 1x4 frame for on the outside for aesthetics. I hung the doors with three strap hinges each. To lock them, I used a pair of deadbolts, one at the top and one at the bottom. You can get extensions to allow the deadbolt to go through the extra thick door, but I simply cut a hole in the inner plywood to essentially make the door thinner in those two locations.

   Chris @ www.flairwoodwork.spaces.live.com
   (soon to be www.flairwoodworks.com)

    - Success is not the key to happines.  Happiness is the key to success.  If you love what you are doing, you will be successful. - Albert Schweitzer

1. 
   d | Mar 10, 2009 01:40am | #8

   I looked at your website and & I do like the doors.  Thanks for the info.

   David