Material to laminate a built-up shed / barn door, AND hinges

[tshep]

I need suggestion!
I am in a HOA (!@#$%^&*) area, and need a no/low maintenance surface for shed doors - the 2 will be 100 x 100. split. (The hole is big enough for my tractor on its trailer.)
I envision a light frame from 2x2 or aluminum angle, filled with foam board for light, rigid fill, backed by thin plywood. (Maybe faced by that plywood instead, per laminate.) I will then 'frame' them on the face with white PVC trim for rigidity, strength, and view in a classic framed and bisected 'X'.

I seek a face material (and suggested source) that will require no maintenance, a plastic or affordable aluminum sheet.
I would prefer a light gray, without 'board' pattern, so far...

Hinges?
They will have siding 'J' extending the doorframe depth (I could notch), and need to go full '180' open (so door depth will not block opening) to clear wheels coming into shed.

Thanks folks!

 

[Carl_NH]

Here's 4x8 sheet in 1/4 or 1/16" - use this and trim with azac oon bith sides and build your X on both sides for rigidity and you can extend the azac 2" over on one side and top/bottom to get the 50x100"

1/4 in. x 48 in. x 8 ft. White Reversible PVC Sheet

Still concerned this may be wobbly / flex a lot - have you considered sliding hanging doors instead of hinges (barn door style)?

 

[WinterDeere]

You can also buy PVC (think Azac) in 4x8 sheets of various thickness. I did then when needing to wrap several posts, just bought a sheet of 1/4" material and ripped what I needed from it. Has an advantage over aluminum or other panels, because you can PVC cement bond between the trim and panel.

 

[tshep]

Here's 4x8 sheet in 1/4 or 1/16" - use this and trim with azac oon bith sides and build your X on both sides for rigidity and you can extend the azac 2" over on one side and top/bottom to get the 50x100"

1/4 in. x 48 in. x 8 ft. White Reversible PVC Sheet

Still concerned this may be wobbly / flex a lot - have you considered sliding hanging doors instead of hinges (barn door style)?

Went for big overhang all 4 sides, 'bird box' returns on gables - it will well match existing garage in view. Eaves will be below door tops.
Thanks for product names - I will pursue!

 

[Carl_NH]

Pictures would be great - please!

 

[bcp]

PVC sheet: HD says none within 100 miles.



Bruce

 

[WinterDeere]

PVC sheet: HD says none within 100 miles.



Bruce

That's a surprise, but maybe try a real building supply or lumber yard. My local (About Shelly's Building Supply Building Supply | Shelly's Building Supply) always has several pallets of 4x8 PVC sheet, in various thicknesses. That's no help to you on the west coast, but a point of reference.

 

[Aussiebushman]

Contact your local metal supplier for aluminium "propeller plate"
This stuff is thin, light, easily fabicated and comes in the usual 8X4' sheets. It can be bonded with polyurethane and/or fixed with sheet metal screws and is easily painted with etch primer and any top coat
.
I have used it on several jobs - especially in boats and wish I had known about it years ago,