Door repair ideas?

[tshawn]

Just purchased a used 2008 Flagstaff Pop Up. The screen door is missing the top and bottom panels, which I figured I could just buy. Called local dealer yesterday and he said he can't get parts for the door, and it's $400 to replace the door! Looking for any ideas on how to replace those panels and keep everything looking nice.

I'm thinking I can just buy some white plastic panel(melamine?) from a big box hardware store and cut them to size. Won't be able to slide them like factory, but should work to keep rain out.

[f5moab]

How about some aluminum sheets? Easy to bend, easy to cut, and maybe connect together with very small screws/bolts or even POSSIBLY, a few TIG tack welds? (Not a welder so not sure on that last part.)

[tshawn]

That might work as well, thanks!

[Still Kickin]

If you have a local roofing/siding gutter supplier. Drop buy and have them cut you a couple lengths of gutter material right off the coil. That thickness beats flashing stock. You can use a framing SQ. to mark and score the aluminum to spec and just bend it back and forth to snap it clean. Stuff ends up sharp, so use some 120 grit sandpaper to dull the edges up. Wear gloves when working the metal.

[2gwright]

I would try a sign shop and see if they will cut your panels from corrugated sign material. It's very light and will not rot or corrode.

[tshawn]

I got the door fixed, looks good and will do the job. 2 corrugated plastic panels cut to size and about 20 minutes of time! You can see the bottom panel here!