Sectional Doors - on the cheap!

[puffernutter]

I have a car port that is covered on three sides and I'd like to put a door on the front to reduce drafts, stop the rain and keep out prying eyes! (I know, so it becomes a garage by stealth!) I am finding it difficult to find a door (roller shutter or sectional) at a price I can afford in a location that's not miles away and the right width for my opening!
So, I wondered about using some triple glazed uPVC panels and strengthening the edges with aluminium channel (trying to get strength without weight). I have all the rollers and hinges (dirt cheap in the US and carried back on one of my trips over there!) and I reckon I can fabricate the channel for the roller. I also have a suitable motor.

Alternatively can anybody suggest an alternative material. I've done some searching, but the only other possibility was insulation panels used in caravans/fridge lorries, but they are quite expensive.
I'm looking for a width of 3m (could be slightly wider and about 4m tall)
Cheers
Peter

 

[Rig Pig]

I just fitted a second hand Henderson garage door to my workshop - if you don't mind re painting one they are cheap as chips second hand.

 

[awemawson]

Peter,

There is a s/h 8 x 8 foot roller shutter door on homeworkshop.org.uk at the moment at a reasonable price

 

[CompoSimmonite]

Plenty of cheap secondhand roller shutter doors around. I've found loads on eBay - only problem was wrong size of distance away. Narrowing a door is relatively easy but obviously widening isn't !
For my carport I was going to use the HD sheets that are found on curtain sided lorries along with the same upper track. Not secure but can be made to block off the bulk of weather. I suppose the lower edge could be weighted or have eyelets added so it could be sealed to the ground with straps around concrete blocks and such

Paul H

 

[Kent]

make one! Few lengths of box, hinges, locks and something to infill. I have a big double stable door done on my place complete with five lever mortise lock cut in to only the escution shows on the front face

 

[puffernutter]

Thanks. I saw that 8' width and was very tempted. The price is very good as well! However I've just measured (again) and I need a minimum of 3m and ideally 3.3m, I also need a minimum drop of 3m. I can't make it any narrower as I occasionally have the "Dog Van" on the drive (partly under the carport), which is a high roof LWB.

Box and infill (maybe that triple glazed roofing material) is a possibility, but for weight it will need to be aluminium - and I haven't the kit to weld ally. I've got a TiG (still waiting to use it!) but it is steel only. Have to see if there is a local fabricator, or any offers from here.....

Cheers

Peter

 

[Kent]

you can in simple format pop rivet galv sheet, ali plate on etc. or infill between flat bar "front plates" with plastic stokbord, t&G in real timber (with ply backing in the smaller stuff) or some plastic t&G it all depends on what you want. Why are you fussed about the weight? As you don't lift them up if they hinge at the sides

 

[puffernutter]

A misunderstanding methinks! Sectional doors are hinged horizontally and are lifted vertically (so weight is important). I have a car parked immediately in front of the doors, so hinged wont work.

Cheers

Peter

 

[puffernutter]

Any takers on here to manufacture some rectangles made out of 20mm square aluminium box with corner gussets to add strength and when I've worked out it with some more detail other strengthening plates where the hinges and the rollers are mounted. I'm still considering the "filler" but leaning towards plastic roof glazing.
If they are 0.5m x 3m each, I would need 6 of them making.

 

[awemawson]

With all that faffing about it's be far easier and probably not much more expensive, to get a used roller shutter off ebay.

I've had several brand new roller shutters made and fitted by a firm in East London over the years for a couple of shops and also my own workshops. The most recent was on my workshop here - its a good 4.5 metres wide and probably almost as high, and motorised, and fitted by them it was under £1200. And that was even including powder coating in my choice of RAL colour. These are solid commercial roller shutters not the wobbly things people have on garages.