![Smile :)](./images/smilies/icon_smile.gif)
Breaking with tradition I have been putting some time actually working on this instead of just thinking about how to do it. The door is a picture frame of white wood 1x4 covered with same polyisoanurate as the box and corner bead trimming the outer edge for abrasion protection.
I used a set of lift off hinges from McMaster Carr
![Image](http://www.mcmaster.com/param/images/hinges/1151a81.jpg)
The door was having some issues that my brother in law helped me work out. The box was racking due to flexing. It now has a permanent location. Ultimately I put my old boil kettle in with about 13 gallons of water to hold it down, then we connected it to the garage wall in a couple places to provide the needed stability. If I were starting from scratch I would have make a complete frame and lined it with the insulation.
I'm using 2 rows of this foam tape made of silicone/EPDM blend for the door seal:
![Image](http://www.mdteam.com/images/products/Wave.jpg)
Two rows of weather stripping. Two row barley. Coincidence? I think not!
I'll try to post some pics. I need to build a cowling for the AC unit, then a test....