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adambrightreg

Design help -- building a trap door in the floor

A B
3 years ago

Hey Houzz,


We are finishing up the major work in a bedroom renovation and we're now trying to tackle a sort of finicky component: the old trap door in the floor.


For background, we're on the third floor of a three-story condo. Previously, this was a storage room that looked sort of like a barn. The trap door led to an emergency set of rear-exit stairs. The flooring was rough-hewn pine subfloor.


We have installed a new, level 5/8-plywood subfloor and we want to maintain the stair access for emergencies. Otherwise, the stairs will never be used. We are installing 1.5-inch birch hardwood flooring.


For reference, the stairs are in a corner of the room, (unhelpfully behind the ladder in this photograph):





If you're looking straight down at the opening for the trap door, it looks like this:



Our vague idea of what we want the finished product to look like is this (random photo we grabbed from the internet):





Here are the nitty-gritty design ideas and questions:


1.) Currently, the trap opening is framed in 2x3s. Our idea is to sister another border of 2x3s along the inside edge of the trap door opening to provide a larger lip to support the trap door. Will this provide a strong enough lip for the trap door?


2.) We obviously want to avoid any feebleness in the design and we don't want the door to warp or flex underfoot. The plywood component of the door will need to be about 54 x 24 inches. Will 5/8ths plywood be stable in that size? Should we use 3/4ths instead? Should we use 1 inch? Is there any specific type of plywood we need to use for this application? (We would adjust the height of the sistered 2x3s to compensate for any height difference between the trap door plywood and the surrounding subfloor plywood.


3.) We were thinking of using one single long exposed piano hinge for the trap door, like in the picture above. Earlier in the design, we had thought about using fancy recessed soss hinges, but decided this may be too tricky. Is one long piano hinge the best approach? (It would need to be placed along the long side closest to the wall in order to be able to open correctly.)


4.) We'd like to create a picture-frame border around the edge of the trap door itself, partly to avoid an exposed line of cut flooring, and partly just because we think it will create a nice aesthetic between trap door and floor. We were thinking of using the 1.5 inch birch to make this picture-frame border and I was planning to affix it construction adhesive and facenailing. Will the picture frame border be strong enough with this approach? Does that seem like the right way to create a visual border for the trap door?


5.) Ideally, we also wanted to build another picture-frame border on the surrounding subfloor edges (so, a double picture frame like the one in the inspiration photo above). However, as you may be able to see from the photo of our trap door opening, the two "wall sides" of the opening have very narrow ledges, of about an inch. We are not quite sure how to finish these. One option we considered is to rip the birch flooring and facenail and/or glue in place. (I'm not sure if that will work.) Another option we considered was to try rig up something with baseboard and quarter-round, but I'm worried that might look terrible. Does anyone have suggestions about how to finish these narrow ledges so that they match the birch flooring and are strong?


We are quite new to home-owning. We are profoundly grateful to you all for your experience and wisdom.


Thank you very much.


Adam

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