If you followed my last thread titled Front Bunk Door Repair, then you're at the right place to see the finished product!! I feel fortunate the weather stayed gorgeous from Sunday to Sunday. I put quite a bit of work in during that time but I feel proud of the accomplishment. A previous owner had done a poor repair by using laminate flooring (1 piece wide across the bottom of the door) to provide a stiffer sleeping surface than the rotten plywood. You can see in the pictures where some type of adhesive was used which melted the styrofoam. The toughest, BUT PERHAPS THE MOST IMPORTANT THING I did was to separate the outside fiberglass piece from the lauan plywood it was glued to. Not all of this came off but I did get roughly 2 inches of the outer edge cut away (this is important later on). What would I have done without being able to re-use the outer shell of the door? How much would a new fiberglass/lauan panel for the exterior cost? The best idea I had was to spot weld two new aluminum braces into the door for extra support. How did the door ever hold two people up in the first place! The there is the new 1 inch thick "blue board" stryoinsulation to replace the old fashioned white styrofoam. Next came the adhesion of the outer shell to a new piece of lauan plywood along with pressing this together overnight. The other piece of new lauan got three coats of exterior white paint to dry overnight. I had considered covering with wallpaper but I'm glad I didnt. Then the next big job, getting the new sandwich panels back into the frame. It was too thick so I had to cut away a small section to thin it down (and the right tools are very helpful with this). Luckily it was tight but with a rubber mallet I got the frame on and finished without any bumps in the road. Total cost about $100. Estimated time spent, somewhere between 10 and 20 hours.
Bunk Door Repair photojournal
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