Posted By Alton on 01/21/2010 12:06 PM
dmaceld,
I see that you used 3/4" Styrofoam (blueboard) insulation between the wood members at the door. Do you see any problems if someone wants to use thicker blueboard? What would be the limiting factors in using thicker blueboard insulation with your system?
Actually I used 1" blue board for a total thickness of 4". Add to that 1/2" drywall and it matches the jamb width of a door for a standard 2 x 4 wall, not 6" as I stated above. The only problem I would see with using thicker styrofoam is matching the jamb width of standard pre-built doors. If custom sizing a door jamb is not an issue than that's a non-concern.
As I see it the limiting factor as far as styrofoam thickness is assembling the sandwich beam, as I called it on my drawings, and keeping it square and straight and the 2 x 6s in line with each other. I prebuilt the beams. The biggest problem I encountered was working with twisted 2 x 6s. Some of the beams ended up with a pretty good twist which complicated the process of installing them in the bucks and hanging the doors square and level. I glued the wood and styro together so keeping the 2 x 6s lined up while screwing them together was a minor challenge as they all liked to slide around while the glue was wet.
As an aside, because of the restriction against untreated wood being in contact with concrete near grade level, and the propensity of wood around a door to rot at the bottom from getting wet from rain, I added a piece of Trex plank to the bottom of each of the vertical 2 x 6s.