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kytruckerman · 08-04-2014, 09:12 PM

has anyone ever had to remove and rebuild a basement door in a 1997 gs conquest classic. if u have please post info on procedure to fix. thanks and safe travels

jjtjr · 08-05-2014, 03:30 PM

I though boats just had rot. That's not the case. Getting the unit ready for vacation this week. I found some rusty screws on the bottom of the basement doors upon further inspection I found the bottom wood was rotted so bad that the screws were not doing anything. I removed the aluminum trim to expose the "wood and found much rot. I removed the wood ( 1" by 2 1/2"} to do this I had to very carefully peel the inner and outer fiberglass skin off just enough to expose the wood. The wood will be replaced with 1" by 3" rect. aluminum hollow stock. The skin will be glued and screw. Then the trim will be placed back on using stainless screws. This will be done on the doors that are just bad for now but when I go to Florida for the winter all the rest of the doors will be done. O I also found the same problem with the refrigerator vent on the side bad wood. The same fix will be done. I will post photos as the project goes along.

kytruckerman · 08-06-2014, 10:44 AM

thanks 4 getting back so soon. your info has been helpful,my only concern is how did you remove the side frame after screws were removed. mine will not come off

jjtjr · 08-06-2014, 07:35 PM

After all the screws were removed I used a screwdriver and pried the side frames going slow so not to bend it and the silicone would let go. Tomorrow I will be picking up the aluminum and will post the fix.
I wanted to remove the doors but can't figure how they come off. I tried to lift them up against the body then pop them from the hinges but that didn't work so I removed the top screws that are the hinge frame and left the hinge there and just pulled the door from the top frames. The doors will be assy with stainless screws.

jjtjr · 08-08-2014, 05:37 AM

Here is a update on the doors. After a closer inspection it was found that not only the wood was wet and rotted the foam was also wet throughout. I know foam isn't suppose to get wet, but the type that is used does. Its made up of little balls of white foam. What happens is the space between the balls gets soaked with water. Its not possible to dry it, It has to be replaced.
After giving it much though and not wanting to repeat this in the future this is what I did and will do as each door goes bad.
Went to the metal supplier we have a good one about 1 hr away and purchased 1" by 3" 12 Ga. rect box aluminum 10' of it. The price was $27.00 then cut it to size and welded to make a new door (No wood). Went to home depot and purchased the blue form 1" thick. Remove the old outer and inner skins from the old door and glue them to the new door. This is still going on today and will update when its done. This is what I have so far. I know it some what involved but I want a long term fix this seems to be it.
The thing that tweaks me is this isn't a lot of $ to do right. I guess it you but a very high end unit you don't have these problems.

jjtjr · 08-08-2014, 07:21 PM

The photos are as the work was done.

jjtjr · 08-08-2014, 07:27 PM

take a look the the sequence of the work.

kytruckerman · 08-11-2014, 07:00 PM

thanks for the pics. u don"t know how much I appreciate ur heilp on this . looks simple enough.let u know when mine are done ,before winter thanks

jjtjr · 08-12-2014, 05:19 AM

When I get back from cape cod gone for 10 days. I will start on the other doors. Now that I've come up with a method it looks like I should be able to do each door done in about 4 to 5 hours. I know I have at least 2 to 3 more to do. I have to get this done before I leave for florida for the winter. I know this fix seems like its a little over the top. My approach is do it once the right way the first time and forget it. The cost was not expensive more then $ 35.00 but less then $75.00. you can't let new doors from GS so this is it.