Tornado Shelter: Building and Hanging the Door

The door is made up of five layers: three sheets of plywood bolted between two layers of sheet metal. The door is an overlay door that swings outward. 

The design was chosen in order to effectively transfer the impact force of an airborne ‘missile’ from the door to the wall. As noted earlier, make sure your local jurisdiction allows outswing doors on shelters before initiating this project.

You Will Need

Materials Needed In This Section

• 3 sheets of 23/32 plywood, 48” x 96”
• 3 custom fabricated 14 gauge steel angles
• 2 sheets of cold rolled (or galvanized) 18 GA steel, 42” x 84”
• 1 2x4, 96” long
• 15 bolts with nuts and washers, 3/8” diameter and 2-1/2” length
• 3 gate latches with 5/8 dia.” slide bolts
• 3 door hinges, 3/4” bolt hook and strap hinge
• 6 bolts with nuts and washers, 3/8” diameter, 2- 1/2” length
• 3 Simpson Strong Tie HL53 heavy angles (or equivalent)
• 85 lag bolts, 3/8” diameter, 3” long

Tools Needed For This Section

• Drill
• 3/8” diameter drill bit
• 1/2” diameter drill bit
• Woodworking clamps

Watch the Video

Instructions

Click on each image below, in order, for specific instructions.

Note: As shown, the steel sheathing is the exact same dimensions (42”x84’) as the plywood. The door may be more comfortable to handle if you order the sheet steel ½” shorter in each dimension. This will prevent the possibility of the steel from slightly overhanging the edge of the plywood that can create a sharp edge to the door.