LeSharo Door repair

[Boots]

Sent: 4/14/2007

I'm looking for the Coach Door Filler material for 84 LeSharo.  My cellulose liner has been moldy and the plywood covering it is shot.  Interested in either one or both before disassembly of door and making a pattern.
Regards,
Boots

[Slantsixness]

Sent: 4/16/2007


The door is simple to rebuild. You can get the foam sheets at Lowes. Replace the wood parts with regular old pine, you'll have to double the insulation foam sheets for thickness. there is a process to Re-bonding the foam to the inside and outside skin:

First, bond the foam together with a suitable waterproof adhesive. then, use PL185 wallboard adhesive on the interior panel to foam and wood parts. on the outside Fiberglass sheet,  coat the Foam side with PL185 adhesive, but on the fiber panel itself, use spray adhesive like the stuff you get from Wilson for countertops. assemble the door pieces and clamp them down Without door framing on. The more even pressure you use, the stronger the door will be. Leave the "sandwich" clamped and under pressure overnight, then re-assemble the door framing.

The spray contact cement by itself, will, unfortunately melt the foam panel, but it's the only adhesive that will stick well to the fiberglass outer skin. the PL185 wallboard adhesive will not melt the fiber-foam panels, and not the inside wood or fiber board backed panel.... but it doesn't stick well enough to the fiberglass or aluminum outer panel. Not doing it this way results in the rig or panel "delaminating" where the bubbles show up down the body line. or the outside panel comes loose and flaps around. In the case of a door, the bad result is a floppy and flimsy door.

Now as far as a LeSharo is concerned, I can only assume that the door is made like any other Winnebago door, and it is made of Thermopanel construction, and it's not a composite or resin door. If I'm wrong there, let me know how it's constructed!

Tom 

[Slantsixness]

Sent: 4/16/2007

Oh yeah. One last thing.... it's late.. forgive me!

You asked about a template. I would use your existing panels as a template, even if they are horrible, they are still closer than another door would be, unless you replace the entire door and door frame together.... and that's a whole different ball of wax!.... anyway... continuing.....assemble the new Sandwiched panel somewhat oversizes, with the wood reinforcements in the right place for the door latches, hinges and such, then cut the entire newly made panel to fit the door framing, after its dry. It's super easy to cut the panels out once they are bonded. Making 3 or four separate layers cut to fit individually takes too much time and effort!
(note: That "door framing" and the "Door Frame" are two different items here. The Door framing is simply the outer aluminum door "edges". The Door Frame  that attaches to the hinges and the motorhome can usually be left on the motorhome.)