Here you can see the grooves for the 1/8 steel rod that will be used to hinge the door. I clamped the door in place with two
pieces of styrene on the top, bottom and the two sides, this was so I could keep the door the proper distance from all four
sides of the door opening. The two pices of plastic would represent the styrene that will later be glued to both the door
and the door frame.
After clamping the door in I ran my Rotozip along a clamped guide so I could groove both the door and frame at the same
After I was satisfied with the way the door was hinged I styrened the inside of the door frame.
I used a two part resin epoxy to glue the rods into the grooves on the door. After that I glued styrene on all six sides of
the door and sanded.
Then I epoxied styrene to the front, I added some white grease to the hinge grooves before attaching the plastic. Clamp it,
tape it and take a break.
I covered all of the front surfaces with styrene including the horizontal panels. I used a 2 part resin epoxy for this it
is very smooth and has a working time of 20 minutes,I used it to fill the seams on the tread sections it dries rock hard and
can be sanded easily.
P.S I got it at Home Depot it's made by the GOOP folks.
I added a bead of wood glue here. Once the tread is textured and painted it made it look like a weld.
I thought that was cool.