On my 2009 Keystone Hideout the side 5' wide toy hauler door is rotten at the bottom. I took the door off and the aluminum frame to see it's a sandwich of luan and foam. Need to rebuild and wonder if anyone else has built a new 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.