The original doors had cardboard "filler" inside of them. Any leaks at all and the filler rotted and you were left with a very flimsy door. If the door skin is okay, they can easily be rebuilt. If you're looking for a totally new door though, Aimee in Alaska was very pleased with the door she had built by these folks:
1961 Scotty Door Rebuild
Remove the jalousy window unit first. This is held in with screws on the inside.
Like the '69 below, the inside of the door was cardboard
New frame made out of white cedar - lightweight and rot resistent
Openings filled in with styrofoam - adds structure, yet lightweight
1969 Scotty Door Rebuild
Remove door window first. It has a locking gasket. Use a screw driver to unlock the gasket and then very carefully remove the window. No easy way to do it - it will be difficult.
the seal and glass from the inside of the door.
The seal (channel) should be replaced with a new seal.
Glass shops should carry it.
left corner of the door in-side. Bottom, top and lock side
of the door
are crimped. We only uncrimped the top and bottom,
the door was then slid out from the hinge side.
edge of door - not crimped
edge (crimped) of door
apart, this is the inside of the in-side.
Inside of the out-side. Completely rotted from the lock down.
Appears that the leakage came from around the lockset.
close-up of the rot around the lockset.
part of the framing still in perfect condition, but cardboard was
used as the stabilizer. I'll use 1 1/4" thick styrofoam in my rebuild!
had some clear white cedar, the exact dimensions as the original
Marking it here for mortices, the most sturdy option available.
the mortices on a dedicated morticing machine.
The first step in creating the tenons to fit into the mortices
The second step in creating the tenons
And the final step in creating the tenons
A completed mortice and tenon
The new frame lying on the door - a perfect fit!
And, the frame - still lacking the styrofoam.
Replacing the fabric hinge cover
The fabric covering of the piano door hinge was disintegrated. In asking around, I was sent to a local shop that does custom sewing for awnings, ATV and snowmobile seat cushions etc. The owner suggested I try a "polymer canvas" which goes by the trade name "Top gun".. He sold me a strip 5" by 6' for $1. He said I probably would never see the end to it. It really does seem quite tough. I replaced mine. A couple of hints in doing so. Drilling out the rivets from the door side was quite a chore, next time I would try removing the door frame first, I had to do this anyway, and drilling them out from the back side. Also, don't forget that extra fabric is needed to close the door, so don't put the fabric tight on an open hinge. I attached to the outside frame side first and then sandwiched between the door and the hinge, closed the hinge (door) and trimmed off the extra.
Top Gun fabric - considered the best outside fabric around!