What material do you use for your pop door?

[Avonshire]

I have seen people use plywood. I have also seen other materials like metal and I guess I am just curious where you would get the pop doors made out of other materials. Thanks! Oh and why use those materials--I can imagine metal is stronger but are there other reasons like more weather proof? Of course I would probably use wood for the track so does a metal door really gain me anything? Would it be more than 4 lbs? My automatic motor can only hold 4 lbs. If you use plastic then where did you get it? That seems like it would be lighter.

 

[canesisters]

"Are you pondering what I'm pondering?"
I was actually thinking about going to a local frame shop and seeing if they would cut me a piece of heavy plexi. Yes... I know I can cut it myself - but since I've never cut a straight line in my life, I don't want to end up with a door that's so woppyjawed that it can't slide up and down - or keeps getting stuck half way.

 

[Avonshire]

a picture frame shop? Do they still exist? Did you buy your plexi glass at Lowes or Home Depot or will you get it at the frame shop? The latter sounds expensive!!

 

[canesisters]

I was just going to stop at Michaels (craft store). Years ago they would cut framing mats for me for like $5 each. Probably would be best to get the plexi at one of the home improvement stores.

I haven't gotten quite that far yet. Just finishing up the floor in my coop and still need to put up a run - so there isn't a door yet. I'll let you know what I find out about it though.

 

[G-Man]

I used two layers of sheet metal glued with contact cement to a piece of plywood that I milled voids in to cut down on the weight. Then I attached an aluminum "U" channel to create the edges of the door to ensure it would operate very smooth up and down the track. I weighed the materials with a kitchen scale before I assembled it.. I was under the 4lb mark that the Add-A-Motor D-20 specifies.

For the track itself I cut a groove in a composite decking material that doubled as the frame with a router bit a little wider than the thickness of the door. The composite decking material has inherent slick properties much like Delrin, which made for a very smooth operating door.

The reasons I chose the materials I did for the pop door and frame was to ensure the door wouldn't warp, then bind in the tracks ruining the motor.

More to your question..
I've seen people use inexpensive cutting boards, which I thought was a great idea. I also think a clear plexi-glass material would work well too. Very lightweight and shouldn't warp. I would look at the big box home stores for the plexi glass.

Good Luck with your project.

Click the link below if you want to see the cost break down of the pop door I made.

https://www.backyardchickens.com/t/628008/automatic-pop-door

 

[chfite]

I made one of mine from 1/4 inch plywood and the other from 1/4 inch OSB. Good coat of primer and paint, no problems. I made the tracks from whatever I had lying around, some pine board and masonite, I believe.

Cross stranded materials such as plywood and OSB are quite durable. I doubt anything less than a bear could tear through it.

Chris