I've been working on two large steel doors (9'2" h x 8'6" w) for a local retail store in Bend, Oregon. It's been quite a project. I've learned a lot about welding light tubing and sheet; before this project I'd never even purchased 22 gauge steel sheet before, much less welded it. I also have never tried to patina such a large expanse - challenging operation! Doors are mostly complete at this point - still working on building the custom rollers and track hardware and then have to install everything. Doors weigh approximately 475 pounds so moving them is tough.
Welded .065 wall 1.5" tube frame sheeted with 22 gauge. installed 1.5" rigid foam insulation inside frame to help dampen sound and take some of the drum effect out of the doors.
After the patina went on, steel trim was installed by stitch welding perimeter and passing some rivets through entire door and plug welding the back side.
Detail of the steel trim. Dozens of rivets - most of them just for show.
Heavy duty rollers!
Long track! Drilling mounting holes on 17' bars meant meant moving the drill press to the middle of the shop.
Doors feel pretty big when they are stood up in the shop. excited to see them side by side when they are installed!
Welded .065 wall 1.5" tube frame sheeted with 22 gauge. installed 1.5" rigid foam insulation inside frame to help dampen sound and take some of the drum effect out of the doors.
After the patina went on, steel trim was installed by stitch welding perimeter and passing some rivets through entire door and plug welding the back side.
Detail of the steel trim. Dozens of rivets - most of them just for show.
Heavy duty rollers!
Long track! Drilling mounting holes on 17' bars meant meant moving the drill press to the middle of the shop.
Doors feel pretty big when they are stood up in the shop. excited to see them side by side when they are installed!
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