My thought it to have the edge trim on the inside and outside of the door frame and an aluminum flat bar on the lower sill for added durability (see image below).
I haven't decided what to do on the other inside door opening edges. I think I will make it simple and cut 1/8" plywood to cover the surface and finish with edge trim. I shouldn't need the same level of durability as the lower sill so this should work.
This image is of the door opening with edge trim cut and positioned. I have also placed a small piece of "T" molding to show the overlap.
Kind of a tough picture to get a bead on. This is "T" moulding purchased from Teardrop Fix-It-Shop placed on top of my unfinished door. The "T" moulding is 3/4" x 1/2". Though it is not as deep as my door, it should work to seal the outer opening nicely. I am very impressed with how easy it is to bend, considering it's shape. I made one rough bend around the outside radius with little problem.
The "T" moulding will be attached to the door with gasket material on the other edge surface. The gasket will seal on the outside edge of the wall and edge trim. All I need now are the door windows and I will be ready to finish this part of the project.
Close-up of the flat bar in place. I just need to drill and counter sink the screw holes.
Wider view of the flat bar in place.
Well, while I was searching at a local steel supplier, I found what I was originally looking for - 1 3/4" aluminum flat bar. I pulled my previous cut pieces off and have put the wider flat bar into place. I will still trim the interior and exterior edges, but I need something slightly wider than the 1/2" moulding I have now.
A different view without the final trim.
