It seems that I have exhausted my options for getting an off the shelf (sort of as they all seem to be built by order, but in standard sizes) composite entry door. Our door cutout and interior cabinets leave too little space for a standard size. GXV won't make a door. So I am now back to building one myself. Not really the path I had hoped but I am pretty sure I can build one. We have been meeting up with a number of professionally built trucks here in Alaska and the door frames do not look too difficult to mold. I'll lay out my current plan and if anyone has any thoughts please jump in.
Epoxy resin will be used throughout. Probably MAS
Mas Epoxies - Time Saving Epoxy Resins as I have used them before and I like the mix ratios and low odor.
Will probably paint the entire door as opposed to gelcoat as I doubt I will get a perfect finish after molding without some fairing. I will get color matched rattle cans with 2k paint like we used on the truck cab (not the rattle can bit, but I don't have a place to spray or a compressor to do it like I did with the cab).
For the frame I will build a mold out of wood (probably poplar as it is pretty straight and true). This will be the full frame with a step in it and will be coated in
Duratec Gray Surfacing Primer in stock | Fibre Glast . Then a few coats of mold release wax.
The fiberglass will probably start with a mat and then some cloth for strength.
For the door I am planning on a 4 part composite. Fiberglass, marine plywood, Divinycell then fiberglass. The Divinycell will probably be the 1" 5lb one. I have used this stuff in the past and it bonds great with epoxy resin. I will make a mold out of poplar and Masonite and coat with the surfacing primer. The hinge edge and lock edge will be reinforced with poplar embedded in the glass (or I may just layup heavier fiberglass, which may be better). I will use a full length SS heavy duty piano hinge.
The door lock will be the KCT Syslock 3 point locking along with their adhesive backed gasket.
For the window I am still searching for a supplier for a pressure compensated double pane tinted glass panel (if anyone knows please let me know). I would mold a custom frame for it so just need the glass. I need to check with Tern about a small roller shade like we have in our bathroom.
I am on the fence, since I will mold the entire bit to mimic the rounded corners of our current door. I like the look and I can say I have seen small corner cracks in some of the very expensive trucks I have been seeing. If so I would build the entire door/frame before removing the current door. I would bond in the door using Sika 252.
My rough estimate is I think I can get this done in about 2 weeks if I plan ahead and have everything sourced and ready to roll.