Toy Hauler rear door
my 2007 KZ 41 has a slight problem with the rear door/ramp. It has some how gotten water in it and has rotten out by the water getting in somewhere. I am looking to replace it with a new one but can't...
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These are not tough to rebuild yourself. Especially if the outer fiberglass sheet is in decent shape. Take the door off. Take apart the outside aluminum trim. You will find one or two layers of cheap plywood under the grip surface that overlay an aluminum square tube frame, usually with foam panels between the framing for insulation. Other side of frame will be luan with fiberglass exterior surface.
Replace rotten wood, the odd size usually means you need to use at least two layers of two pieces of thin luan plywood which comes 4x8. Make your seam vertical (when door is closed) and interlock the two layers by gluing them together with hardwood floor adhesive-full coverage troweled down. Use whatever grip surface you like (rubber diamond plate is nice) and glue that to surface.
If the fiberglass side is rotten, make the same plywood sandwich and you can paint with marine (Interlux Perfection is very nice) after bondo/mesh over seam. Otherwise just reuse the outside layer.
Reassemble the outside trim and brackets. It's an easier job that it even sounds.
Replace rotten wood, the odd size usually means you need to use at least two layers of two pieces of thin luan plywood which comes 4x8. Make your seam vertical (when door is closed) and interlock the two layers by gluing them together with hardwood floor adhesive-full coverage troweled down. Use whatever grip surface you like (rubber diamond plate is nice) and glue that to surface.
If the fiberglass side is rotten, make the same plywood sandwich and you can paint with marine (Interlux Perfection is very nice) after bondo/mesh over seam. Otherwise just reuse the outside layer.
Reassemble the outside trim and brackets. It's an easier job that it even sounds.
