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Lightweight exterior doors

KylefromKy | Posted in Construction Techniques on March 1, 2015 05:52am

Hi all,

I’m building a tiny house on wheels which will have a small shed attached to the front of it, sort of like an exterior closet. I’m looking for ideas on how to build two vertical shed doors, each one about 30″ wide  x 70″ tall,  so that they are light weight, strong, and suitable for exterior use.

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  1. DanH | Mar 01, 2015 07:47pm | #1

    Well, the first thought would be to use fiberglass exterior doors, but finding ones in that size is unlikely.

    1. KylefromKy | Mar 01, 2015 08:14pm | #2

      That's interesting. Aren't fiberglass doors on the heavy side? I haven't had much experience with them.

      1. DanH | Mar 01, 2015 09:31pm | #4

        They're only heavy if they've been intentionally made heavy.  Which is no doubt done to some to make them seem more substantial.

  2. calvin | Mar 01, 2015 09:25pm | #3

    Kyle

    Travel trailer or sit in place?

    1. KylefromKy | Mar 02, 2015 05:22am | #5

      Travel trailer

      1. calvin | Mar 02, 2015 05:33am | #6

        Kyle

        so there's potential for 60 mph rain?

        how about a salvaged work trailer door.  Tight locking and good seal.  There's also a lot of different sizes on horse and race car trailers.

        1. KylefromKy | Mar 02, 2015 09:22am | #7

          Very interesting idea. I think the owner is looking for something with a more cottage-like appearance, built out of wood possibly. The waterproofness is not critical, as it should contain things like shovels and garden hoses.

  3. erinmg85 | Mar 02, 2015 11:18am | #8

    Hi Kyle! We're also builing a tiny house on a trailer and trying to figure out the hitch shed doors right now... Our plan is currently to use 1x4s mounted to plywood, then trimmed with more 1x4s. We're basically copying the design of a shed that's currently sitting in the backyard we're building in.... it just hangs on a couple of hinges and closes using a hasp, which we'll put a lock on/ I've attached a couple of sketchup pictures of the plan. We should be building it in the next couple of weeks.

    1. KylefromKy | Mar 02, 2015 02:21pm | #11

      Sounds like we're doing just about the same thing. Are you going to have one by fours on both sides of the plywood, inside and out? What thickness of plywood are you planning to use? Are you concerned about the plywood warping?

      i've attached a photograph showing the pentagon shaped perimeter where the shed will be attached.

      1. erinmg85 | Mar 04, 2015 02:35pm | #16

        We're planning on having the 1x4s just on the front, and using 3/8" plywood (actually, that plywood siding with the lines/grooves in it). Hopefully this will be sturdy enough. If the plywood does seem like it's warping, we may reinforce it with 1x4s on the back as well. Our doors are a bit smaller than yours though -- each is only about 48" tall and 20" wide -- so you may need to use a bit sturdier stuff.

        Your tiny house is looking great by the way!

        1. KylefromKy | Mar 04, 2015 02:57pm | #17

          Thanks. I have a blog, which I haven't updated in awhile, if you're interested in visiting it.

          http://buildingatinyhouseonwheels.blogspot.com/?m=1

  4. sapwood | Mar 02, 2015 11:55am | #9

    If it were me, I'd build these doors by sandwiching some xps foam between sheets of 1/4" plywood, with solid wood edging all around. A vacuum press makes light work of it but it can be done using cauls and clamps. I've use polyurethane glue in this application with complete success. The doors will be flat, lightweight, and insulated. 

    1. KylefromKy | Mar 02, 2015 12:21pm | #10

      So, I'm guessing it's the solid wood edging that keeps everything flat?

  5. oldhand | Mar 02, 2015 03:42pm | #12

    My first thought would be a frame and panel door, 5/4 or 6/4 rails and stiles with a full 1/4 or 3/8" plywood panels.

    A simpler option would be a sandwich door of outer layers 5/8-3/4" and 1/4'' or 3/8" panel.

    All would need a serious painting, well maintained. With all the details well attended to that should last a good while.

    1. KylefromKy | Mar 02, 2015 05:48pm | #14

      I like the frame and panel idea. What kind of wood would you recommend for the frames? Would cedar work?

      The rest of the house is sided with cedar clapboard's and trimmed with cedar 1x3's, so that would look pretty good.

      1. oldhand | Mar 03, 2015 08:13am | #15

        yeah..

        Cedar would be a good choice. Nice, straight grained as possible.

  6. DanH | Mar 02, 2015 04:02pm | #13

    One could use plastic panels, similar to what's used for chicken houses and the like, for the door surfaces.

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