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Old 04-05-2015, 10:54 AM   #1
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Rebuilding damaged cargo door

The door that covers the propane fill was damaged when we bought it. I m looking for suggestions on rebuilding it myself.

Does anyone have any links to DIY instructions/videos of this being done?

Three sides of the frame seem to be in good shape. It's the bottom that is damaged the most.

Another dilemma: How does one detach this door from the RV? I was thinking about drilling out the rivets along the top where the hinge is to get it off.

Thanks for any info,eh?
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Old 04-05-2015, 12:59 PM   #2
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Not sure how to rebuild the door, but most class a rv's have the doors attached in a channel at the belt line. Remove the door at the back, and slide the rest off the track until you get to your door, then slide it off. You can slide the others back on while you repair the one.

Good Luck!
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Old 04-05-2015, 04:54 PM   #3
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While my warranty work was being performed I spent ALOT of time roaming around the repair facilities of the local dealerships.

Your damaged cargo door is a very common issue, usually caused by gas station pump protection poles extending outward while the driver is attempting to pull in. That damage is also commonly caused by RVPark campsite utility hookup pedistals moving into the path of the coach while it's backing up. It's an epidemic!

The standard fix that I observed on at least seven coaches in a six month period was to:

- remove everything bent, (drilling out rivets where applicable).
- replace all bent moldings, (usually held with double sided tape).
- match paint where necessary
- reassemble
-polish up really nice afterwards and you can't tell that anything happened

If you can accomplish the work yourself you will ave a fortune. For the damage in the picture I can easily see professional RV body repaor quotes of $4,000 to $9,000, (especially when an insurance claim is involved).
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Old 04-05-2015, 05:23 PM   #4
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I had to remove 3 doors to repair. On my coach the door is hinged on a track that is mounted to the side of the RV, it has a round type extrusion that accept the door side.

In my case I had to replace a portion of the hinge on the RV & the 3 on the doors. The hinge was completely flattened on 2 doors and ~1/2 way on the other. Bought the door portion from Monaco and a 7' used piece from a salvage yard. I painted the pieces before I reattached to the RV & Door. The door hinge was held on by 6 or 8 rivets, some on the outside and some on the inside. I had to drill these out to replace. I did not have to replace any skin, 2 doors had heavy scratches and 1 had a deep dent/bow. I sanded the paint down to bear metal and primed. I was able to straighten the bow and used a little filler to make it all smooth. I then painted. everything after it was reattached to the RV. 3 colors, 2 shades of green and black. Then 3-4 coats of clear. Cost was ~$600 for all the supplies.

If you think you will have to replace the skin on the door then you could go ahead and drill out the rivets but it will be harder to put the door back on. If you can slide the door off the hinge it would be better, easier to work on and then you can paint the whole thing. New skin can usually be cut and bent to size at auto body shops specializing in antique renovation.

Good Luck
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Old 04-07-2015, 11:30 AM   #5
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Quote:
Originally Posted by draboo View Post
The door that covers the propane fill was damaged when we bought it. I m looking for suggestions on rebuilding it myself.

Does anyone have any links to DIY instructions/videos of this being done?

Three sides of the frame seem to be in good shape. It's the bottom that is damaged the most.

Another dilemma: How does one detach this door from the RV? I was thinking about drilling out the rivets along the top where the hinge is to get it off.

Thanks for any info,eh?
If you can work on the rig where it is parked, I would be tempted to try to straighten the door edges with some 2x4 and some clamps.

If that result is acceptable, then I would sand the damaged area and use some body filler, like Bondo, to smooth the surface. (Watch some videos on YouTube if you are a beginner like me.)

Then source some primer and paint and use spray cans to repaint the surface.

If the above works to your satisfaction, you will have about $100 invested, mostly in paint.

Also, you will not have to remove the door.

JMHO
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Old 04-11-2015, 10:05 AM   #6
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Thank you for all of your suggestions. I took off the bottom channel with the curve on it and did my best to straighten it. Not much luck there.

I then went to a place called "Steel Outlet" here in Roseburg,OR to get a sheet of aluminum to replace the one on the face. I showed them the bottom channel with the curve piece that I took off, and they said they can make one for $90 tops.

So, the new aluminum sheet for the face is $23, and the bottom channel is $90. My neighbor is going to spray it for me. So, it will end up costing me aboot $150 tops to get a brand new looking door.



I m a happy camper!
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Old 04-11-2015, 10:08 AM   #7
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Good to have talented neighbors

How were you able to remove the door??

If possible post a picture when your finished.
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Old 04-11-2015, 10:23 AM   #8
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Originally Posted by jacwjames View Post
Good to have talented neighbors

How were you able to remove the door??

If possible post a picture when your finished.
No need to remove the door. All work will be done without removal.

I haven't figgered out how to remove it without extensive disassembly.

I'll definitely post a pic when it's all purty and stuff!
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Old 04-11-2015, 11:49 AM   #9
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Excellent solution. Thanks for posting the result.
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Old 04-29-2015, 08:06 AM   #10
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It took a bit of time, but I got 'er done! Total cost was around $250, with over half of that for paint/reducer/hardener. I think it turned out real well. click here for pics
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