We wanted to keep our original door for various reason. Money and having to special order a door was part of that. So this is what we did. Lowes has a retractable screen door (looks like a sideways roller shade) that looks like it may work for a screen door. We'll see. But for now...
Building an Original Bluebird Two Piece Door into a One Piece Door
Because our original door was in such good shape and needed no repairs made to it due to rust. We decided to reuse the door. The two piece door took up a lot of room and we couldn't come up with a good way to lock it. I had gotten a couple lengths of (never used) steel landscape edging off Freecycle.org. It was very simple to do. David removed the door by unscrewing a pile of little screws that held the door onto the piano hinge. Then he trimmed down the piano hinge using a cut off wheel and my small hand held trim router. We also stripped all the hardware and trim off the door. We had several sets of old door hinges so we used them to hinge the door. We laid the door, face side down, on a flat surface and used a straight edge and shims to make sure the door was completely flat. We cut a strip of polyiso foam board insulation to fit tightly inside the groove between the two door panels.We measured and trimmed the length of the landscape edging to fit the door. Then we clamped the trimmed edging to the door so that it wouldn't move. We drilled small pilot holes thru the edging and the door. We reused the tiny screws that were used to attach the piano hinge to the door. Then we rehung the door. A chain connected to threaded eye bolts will prevent the wind from catching the door and tearing up the hinges. As you can see the landscape edging just fit between the two panels of glass.
We cut the original hinge off the door. Then rehung the door with 6 door hinges bolted to the door with screws and nuts. The other side of the hinge wast attached to the frame with screws from the siding.
Turning the original in-swing bifold door into a one piece out swing door.
The chain helps keep the door from swing out too far and damaging the hinges. The center strip is a section of metal landscape edge attached with screws. The small gap was filled with a piece of foam board insulation, cut to fit.
Close up of the metal landscape edging strip.
Another close up. The metal edging fit just between the two glass panels on the door.
This was cut-& pasted with a little addional info added from our webpage. It can be found at http://aluminumasylum.webs.com/bluebirdfe.htm
These photos can be found at http://s570.photobucket.com/albums/s...%20Conversion/
A copy of the article "One Piece Eagle Door" can be found online at http://aluminumasylum.webs.com/onepieceeagledoor.htm
It used to be all over the internet but now it's gone. No pics because I didn't know how to save at that time.
(NOTE: This info is now in Dave Galey's second edition printing of his "The Bus Converter's Bible". I definately recommend that you purchase this book. It is invaluable if you are converting or thinking of converting any kind of bus. 2/2006)