needs some ideas

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a friend of mine is building a trap door for someone. the door is in the floor and it will be opened on a daily basis, the door will also double as the floor so people will be walking on it. it will 4'x8' 3/4" plywood. he wants me to build a aluminum frame for the wood to sit on and he hopes to use gas shocks to assist in opening it. this door is going down to a secret room or "man cave". his idea was to build a frame out of 1 1/2" square alum tube with a cross piece every foot. I know this sounds confusing but has anyone done anything like this? I am all ears, throw me your ideas, different material? what thickness? different design? I tried to make drawing on "paint" but it won't upload on here for some reason
Reply:We have something similar to this for vault entrances in floor spaces. Only difference is they use steel plate with a coil spring assist. They also have a side bar that rides in a slot and pops into a locking position that has to be released before the door can be closed. Special latch with a removable handle on the top side and permanent handle on the bottom side. So basically it's very doable. The devil is in the details. Sounds like a fun build with a few problems to be sorted through.
Reply:I would use .160 thick AL or better. Sounds like an awesome project. Schucks auto supply and Autozone both sell gas shocks for hatchbacks and such. You will just need to attach them to your frame. Seems to be a pretty large opening but I think you are on the right track. It would be interesting to see pics of similar projects people have done.Also, be sure to take many pictures
Reply:I made something like that for access to the old cistern/water storage under the kitchen in my old farmhouse up in NY. The cistern has been changed into a wine cellar with direct access through the kitchen floor. The center island in the kitchen is mounted on rails and slides back to reveal the access panel and stairs into the wine cellar. I am not at my house up in NY but if I was I would take a few pictures to show you. The access panel is abut the same size as what you have planned but instead of aluminum I used old metal bed frames for the panel framework and floor support structure. I used an electric actuator as the lifting mechanism with a pressure activated  switch mounted on the kitchen floor so when the island slides back the access will open. Kind of like out of James Bond movie.The electric actuator came from northerntoolCo-Own CNC shop:Miller :1251 plasma cutter, MaxStar 700 TIG/Stick, & XMT 456 Multiprocess Welder.&  2 Hypertherm HPR260's Plasma CutterSorry I had a bad stroke but now I am back.
Reply:Is the large opening to accomodate a large beer cooler and dancing girls...????I'm sorry, couldn't resist.
Reply:Maybe get a complete hatch back door from a Dodge Caravan and salvage the hinges, shocks, springs and lock mechanism? Get one with body damage for almost free at a junk yard.  I also like that idea of using a bed frame for the base- rigid/cheap/sturdy.
Reply:You'll have a heck of a time getting automotive gas shocks to a) open a 4x8x3/4" door (that's a heavy hunk of wood right there, and b) opening wide enough to allow stairway access.
Reply:Whatever you build, consider a railing to prevent someone falling down the hole while the door is open.See attached video of unfortunate woman and trap door.[ame]http://www.youtube.com/watch?v=YzZ7aGO8PiQ[/ame]
Reply:and the rest of the story[ame]http://www.youtube.com/watch?v=6VjIg1p9yDo&feature=player_embedded[/ame]Ed Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge