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Making a weather resistant door

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Making a weather resistant door Daniel Prince 04-20-2008
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Posted by Daniel Prince on April 20, 2008, 9:37 am
My house has an exterior door on the South side for a small closet
that holds our gas water heater. The door is 24" by 48". My house
is in Los Angeles so there is lots of sun, some rain and no snow.

When we looked at the house before we bought it, there was a plywood
door that was falling apart. The termite people replaced the
plywood door with a hollow core door.

The hollow core door soon started coming apart because of the rain
getting it wet. I looked at Home Depot but did not find a door that
size so I glued it back together with a construction adhesive in a
caulking tube that was supposed to be waterproof.

The door is coming apart again so I want to make a new door out of
exterior grade or marine grade plywood and coat it with several
coats of spar varnish, marine grade epoxy or some other finish. I
want something that will last at least 20 years.

Marine grade plywood is quite a bit more expensive than exterior
grade. Would it be worth the extra cost in this application?

What would be the most cost effective finish for this application
(assuming my time to be worth $10 per hour)? Thank you in advance
for all replies.
--
Whenever I hear or think of the song "Great green gobs of greasy
grimey gopher guts" I imagine my cat saying; "That sounds REALLY,
REALLY good. I'll have some of that!"

Posted by Edwin Pawlowski on April 20, 2008, 9:51 am

> I
> want something that will last at least 20 years.
>
> Marine grade plywood is quite a bit more expensive than exterior
> grade. Would it be worth the extra cost in this application?

>
> What would be the most cost effective finish for this application
> (assuming my time to be worth $10 per hour)? Thank you in advance
> for all replies.

Any exterior door material properly painted and sealed should last 50 years
or more.

If you want or have to build something, I'd use the marine grade plywood and
frame it with solid wood to help keep water from getting in between the
laminations. Over time, that can cause problems. I'd also look at using
MDO. A sheet of MDO looks like plywood and is the material used to make
road signs. It has a smooth finish on both sides and can be painted.



Posted by dadiOH on April 20, 2008, 2:55 pm
Daniel Prince wrote:
> My house has an exterior door on the South side for a small closet
> that holds our gas water heater. The door is 24" by 48". My house
> is in Los Angeles so there is lots of sun, some rain and no snow.
>
> When we looked at the house before we bought it, there was a plywood
> door that was falling apart. The termite people replaced the
> plywood door with a hollow core door.
>
> The hollow core door soon started coming apart because of the rain
> getting it wet. I looked at Home Depot but did not find a door that
> size so I glued it back together with a construction adhesive in a
> caulking tube that was supposed to be waterproof.
>
> The door is coming apart again so I want to make a new door out of
> exterior grade or marine grade plywood and coat it with several
> coats of spar varnish, marine grade epoxy or some other finish. I
> want something that will last at least 20 years.
>
> Marine grade plywood is quite a bit more expensive than exterior
> grade. Would it be worth the extra cost in this application?

No. Coat it with epoxy, especially the edges. After a week or so, wash it
well to remove the amine blush. It will still probably warp.

IMO, you'd be better off making a stout frame and covering it with well
attached ply then epoxy.

> What would be the most cost effective finish for this application
> (assuming my time to be worth $10 per hour)? Thank you in advance
> for all replies.

Paint. Lasts best too. Varnish will require constant maintenance. If you
varnish, it is pointless to use spar varnish.

--

dadiOH
____________________________

dadiOH's dandies v3.06...
...a help file of info about MP3s, recording from
LP/cassette and tips & tricks on this and that.
Get it at http://mysite.verizon.net/xico




Posted by Jeff on April 20, 2008, 5:20 pm
We have a south facing fiberglass door that looks good as new after 15
years.

> My house has an exterior door on the South side for a small closet
> that holds our gas water heater. The door is 24" by 48". My house
> is in Los Angeles so there is lots of sun, some rain and no snow.
>
> When we looked at the house before we bought it, there was a plywood
> door that was falling apart. The termite people replaced the
> plywood door with a hollow core door.
>
> The hollow core door soon started coming apart because of the rain
> getting it wet. I looked at Home Depot but did not find a door that
> size so I glued it back together with a construction adhesive in a
> caulking tube that was supposed to be waterproof.
>
> The door is coming apart again so I want to make a new door out of
> exterior grade or marine grade plywood and coat it with several
> coats of spar varnish, marine grade epoxy or some other finish. I
> want something that will last at least 20 years.
>
> Marine grade plywood is quite a bit more expensive than exterior
> grade. Would it be worth the extra cost in this application?
>
> What would be the most cost effective finish for this application
> (assuming my time to be worth $10 per hour)? Thank you in advance
> for all replies.
> --
> Whenever I hear or think of the song "Great green gobs of greasy
> grimey gopher guts" I imagine my cat saying; "That sounds REALLY,
> REALLY good. I'll have some of that!"



Posted by Daniel Prince on April 20, 2008, 8:20 pm

>We have a south facing fiberglass door that looks good as new after 15
>years.

Do you know where I can get a fiberglass door that is 24 inches
wide?
--
I don't understand why they make gourmet cat foods. I have
known many cats in my life and none of them were gourmets.
They were all gourmands!

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