mtmcj wrote:
Well I spent the weekend rebuilding the door. No more wood in there now, I used 1" thick dow corning super tuff rigid foam board, put two aluminum channels in the foam they where 2 1/2" wide by 46" long with a 1/2" intrusion into the foam. A sheet of white aluminum for the inside and reused the filon siding for the outside. Glued it all together with 3m 90 industrial adhesive. Less than a $100 in material and 1 1/2 days of work. oh and sealed up the outside channel with dap 230 clear sealant. Door is lighter than factory and if anything more rigid. Looks good and works great Now if any water gets in there it will not rot. Only concern is the struts are a little strong for the door now but I will keep my hand on it when opening. Now to seal the crack in the toilet.
Awesome!
I still need to fix mine, it's holding with the long brace I've screwed onto in it for the left side bracket, but it's just a matter of time before that gives.