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I knew this door would be a large project itself. The door weighs about 400 pounds and is 8' 9" square. The goal was to make a strong, warp resistant, insulating, weather tight door (tall order!). Yes, I could have used a high quality garage door, but the problem with overhead doors is that the track and mechanism take up space in the shop. The goal was to have a clean look to the inside with no height problems. I also felt a sliding "barn door" style would give the shop some character, I just did not want a plain looking box for a shop. The opening is wide enough to be able to pull my truck in to load or unload tools, supplies or projects. The door is constructed as a sandwich of 1.5" ridged foam with 3/8" bead-board plywood skin glued on both sides. There is a skeleton 2x4 frame, that holds the window frame in and forms a tongue that fits in a grove of the doubled-up 2x6 frame. The transom window was a great deal which I found at a Habitat for Humanity reuse center. It is 1'x 6' double glazed exterior window that had never been used and was a steal at only $30.00, purchased about 6 months before needing it, but was too good a deal to pass up.
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