I've been thinking about this for the last year--finally got a chance to do it.
The issue--the folding door, opened and closed by a noisy electric motor. I wanted to put a standard RV door on the bus, but my better half is attached to the original door, so we decided to keep it. However, the noisy motor had to go. After doing a lot of reading and planning, I decided to take the door off, cut the center hinge out, splice the two halves of the door together, and then re-hang it.
This has to go!
The bolts holding the door on the hinges came off easily enough, but the center hinge was riveted! At first I tried to grind the rivets off while the door was in place, but I ended up with sparks in my hair and all over my arms, so I decided to take the door off. Actually this worked much easier and got the sparks and noise outside the bus.
The door was pretty heavy, but I was able to get it onto sawhorses and grind the rivets off.
One side free of the center hinge.
I'd bought a strip of metal 6 1/4" wide at a metal yard. I primed and painted the metal, then after drilling holes in the door, clamped the metal in place and used the drilled-out door as a template for drilling the expansion strip.
Because the door weighed so much, I then unbolted the expansion strip from the first half of the door, and repeated the process with the other half of the door, which I'd re-hung in the doorway to check measurements. Of course, I had to remove the half of the door I'd re-hung, then measure, drill, bolt the expansion strip to that half of the door.
I didn't want to try to move the entire door + expansion strip as one piece, so I rehung the door with the expansion strip, then bolted the other piece on. Made sure all the bolts would fit, then tightened everything down. It looks pretty good, although the new paint on the expansion strip got a little scraped up and I'll need to do some touching up. Now for a lock!
I used 12 guage steel--does anyone have any experience with doing this? I'm tempted to put a few cross braces one the inside just to be sure it's completely stiff. I also need to put up something for the door to close against, with some weatherstripping or rubber backing to keep the door-slamming down. I also need to add a metal strip to the bottom of the door, to replace the rubber sweep which is going away. I'll be interested to see how much wind noise I get the first time I drive down the freeway with this setup.