how do I make a storage shed door?

[sixto]

The door of our storage shed is warped and rotting in a corner allowing the elements and who knows what else into the shed. The existing door is a 6 x 4 foot plywood sheet with reinforcements. All I know about wood is that it comes from Home Depot, and maybe from trees at some point prior. Assuming you're talking to a preschooler, hat type/grade/characteristics of wood do I get for the main door panel? Should I use wood or angle section metal for reinforcement? The existing door has 2 x 2 inch reinforcements on the inside, 1 x 4 inch non-structural trim on the outside.

Thanks,
Sixto
87 300D

[The Clk Man]

I would just use the old door as a template.

[elchivito]

Originally Posted by The Clk Man

I would just use the old door as a template.

Words of wisdom right there.

[The Clk Man]

Originally Posted by elchivito

Words of wisdom right there.

I have my moments.

[jplinville]

Take a picture of the shed so I can see what style it is. There's many options available at this time, but only certain ones will fit with the shed style.

[sixto]

I expect nothing less of you.

Now...

It's an even 48" by 72". Home Depot will cut it for me. But cut what? Which 3/4" plywood should I choose?

Sixto
87 300D

[sixto]

It's very much like this except the roof crease is transverse -



The current door is a 3/4" plywood. I'm not after recreating the trim. I'm just after getting the right material to use in the replacement door. FWIW, the shed manufacturer will sell me a door for about $300. The original door is reinforced with 2 by 2s on the inside. From what I saw in the showroom, new doors are reinforced with angle section metal and have insulation.

Sixto
87 300D

[jplinville]

Standard 3/4 plywood with 1X2 cross bracing and edges would suffice. Seal it with a good oil based primer before painting and bracing, and keep an eye on the edges, about 2 inspections per year, looking for more rot. Home Depot can cut all pieces for you, leaving you to assemble the door using wood screws. As for hinges, normal strap hinges would work well.

Simple, yet effective.

[The Clk Man]

Originally Posted by sixto

I expect nothing less of you.

Now...

It's an even 48" by 72". Home Depot will cut it for me. But cut what? Which 3/4" plywood should I choose?

Sixto
87 300D

T-111 is a good choice.

[barry123400]

Three quarter inch douglas fir plywood is fairly rot resistant. Depends on availability and price in your part of the country.

You may have an even equal or greater rot resistance type of plywood available there as well. Make sure it is exterior grade stamped as that means waterprrof glue usually. No waterproof glued plywoods can delaminate as you probably are well aware.

I was surprised at the specis of trees used in plywoods only a couple of thousand miles south of where I live. We never had access to many of those specis of lumber or plywood up here.

Ask if they have any damaged sheets where you shop as one corner even seriously damaged is inconsequental to your needs.

[cmbdiesel]

Originally Posted by The Clk Man

T-111 is a good choice.

another moment right there...

I'd avoid the 3/4 material unless you really like a heavy door that tends to stress the hinges.

2X4 as bracing is a little easier to work with, but hold it back from the latch side a half inch or so to keep it from hitting the jamb.

[mgburg]

One thought you might want to consider...

Think about splitting the door in half...less weight on each set of hinges, do an overlap with the "working" half side and with the less weight on the hinges, you can "beef up" the inside framing of the plywood to counteract the flimsiness of the plywood...

[barry123400]

Yes the single door is a little on the large size. Two half doors are actually easier to use and far more manageable in a wind. Plus the materials used can be reduced in size.

I never remember seeing sheds with only one large door of that size usually come to think about it. It would make access to the sheds very difficult in even fairly moderate winds coming in certain directions.

[sixto]

My memory sure ain't there. Here is the actual door:





The door is 1/2" sheet with 3/4 x 3-1/4" framing inside and out. No 2 x 2s anywhere.

You're going to make me align two doors??? I'll have trouble aligning one. The door still swings nicely and the shed is over 20 years old (dang!). Wind has never been a problem. I swing the door open and prop a rake.

Sixto
87 300D

[The Clk Man]

Originally Posted by cmbdiesel

another moment right there...

I'd avoid the 3/4 material unless you really like a heavy door that tends to stress the hinges.

2X4 as bracing is a little easier to work with, but hold it back from the latch side a half inch or so to keep it from hitting the jamb.

Since I'm doing so good, can I have a cookie?