Anyone built a new ramp door?

I helped a friend tackle this recently. Could not use thicker wood on inside as the door would not close without spacing the hinges to accommodate the thicker door. Luan was used. Diamond plate aluminum was considered but he had no time to source a piece cut to fit. Outside skin was intact and reused, but one could also use a sheet of aluminum there as well if you have the ability or availability. Would be lighter and likely better all around. Good luck with the project!

I ordered the filon and can reuse the aluminum perimeter frame. Took off the remaining hardware on the door. Been reading Portscaner's post and it sounds like his door was built different then mine. I will see how much I can apply. Have not scraped off the Luan yet to see how the whole door is constructed, just the rotted part.

Yeah, me too. Mine is the full size door at the rear and using lots of lumber will add a whole lot of weight.

Ran into the same trouble with the photos. I need to find the correct balance between strength and lite weight.

A lot of the old posts have had the photos removed/made unavailable by PhotoBucket, so it's hard to follow the details.

Post up some details and photos if you would please, I need to check out mine next summer and haven't really decided to jump in yet and just do it.

Search of the archives might help you out ramp door rebuild

Since it's a smaller door I thought of rebuilding with 3/8 plywood with a foam core. Don't know how much weight it would add.