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Old 11-08-2010, 11:01 PM   #1
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Cool Front Bunk Door Repair

Well its a perfectly dry week here in western N.C. so I decided now is the time to remove the front bunk door on my '99 Shamrock 21 to "attempt" some repair. Progress is good so far...done some scraping/sanding and figuring out how the door is made. My question for the forum is--how do these doors hold two people up?? I mean really this is two luan boards sandwiched around styro and a small frame with one center bar. I thought the point where the door poles attach were supported by a cross member but no they aren't! Past water damage has made the portion closest to the hinge essentially disentegrated so I plan to put a new board on the interior. Second question--would it be appropriate to put hardboard material here instead of luan. They are very close to the same thickness. I have a piece on my workbench as a protector and the stuff is tough. The nice thing too is I can get it in the "dry erase" type on one side and that is enough to make the interior visually pleasing because it is nice and shiny white. My third question is on the outside. I have considered calling FR and getting a price on the exterior panel. Since I'm new here I don't know how good of an idea calling the factory for anything like this is.

Thanks
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Old 11-09-2010, 08:24 AM   #2
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give it a try, I would think you could just order a replacement door, but I bet you can repair it better.

What is Luan?
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Old 11-09-2010, 07:49 PM   #3
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You can get anything from the Forest River parts department, they are helpful.
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Old 11-09-2010, 08:35 PM   #4
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What is Luan?
Closely related to mahogany but not a true mahogany. It is also called "Philippine mahogany" (White Lauan from Shorea almon or Red Lauan from Shorea negrosensis), usually used in thin plywood sheets, most commonly 1/4" that is used as an underlayment for floor coverings. Tight grain.
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Old 11-09-2010, 09:12 PM   #5
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Another question....I am thinking about having a couple cross members welded into the door frame for more sturdiness. Anybody disagree?
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Old 11-09-2010, 09:15 PM   #6
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a new door with installation by the local dealer was going to be over $1000. I am fast learning that campers are a handyman's common task so I am doing the work myself for hopefully under $20.
I need suggestions on glue material....would a contact cement rolled onto luan be ideal or would something out of a caulk gun or gorilla glue be better or nearly the same?
I might be giving FR a call tommorrow about the exterior panel only...will post what I find out.
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Old 11-09-2010, 11:02 PM   #7
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I believe you need a glue specially made to bond to styro. Some glue will react with the foam to the point of melting it. I know there are things off the shelf that load in a caulking gun. try the big box stores.
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Old 11-11-2010, 09:03 PM   #8
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bunk door update

$20 !! what was I thinking??? Oh well, I have bought some materials. They include contact cement, a roller for that, tube of foam adhesive, a piece of aluminum for extra bracing, two pieces of lauan, one blue board (foam insulation), a scraping blade for my oscillating tool, and some epoxy glue to fix a crack. So I'm in for nearly $100 now but its going well so far!
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Old 11-12-2010, 08:48 AM   #9
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Good luck shamrock, do take pictures.

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$20 !! what was I thinking??? Oh well, I have bought some materials. They include contact cement, a roller for that, tube of foam adhesive, a piece of aluminum for extra bracing, two pieces of lauan, one blue board (foam insulation), a scraping blade for my oscillating tool, and some epoxy glue to fix a crack. So I'm in for nearly $100 now but its going well so far!
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Old 11-21-2010, 07:50 PM   #10
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for those interested in pics of the finished door, I started a new thread under the general discussion titled Bunk Door Repair Photojournal
I'm pleased with the outcome of the door.
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