I don't know what you call this thing, but my daughter has just bought an older home for her children and neices to live in near the university most will be attending.  There are outside steps leading to a basement door and there is a cover over the steps to keep rain, leaves, and potentially intruders out.   It is quite rotted and I'e been tasked with making a new cover.  The current one is 50" wide and 56" long and in two parts that hinge open.

 

I'm looking for good alternatives.  My initial thought was metal roofing panels, but most are 36"+ wide that makes them too wide.  One source (Menards) will custom cut them to length, but I'm still worried that cutting the metal (painted or galvanized) will expose steel that will rust.  Other options include 2.16' or 2.2' wide (that works better) polycarbonate, PVC, or fiberglass panels.  These will not rust, but not as strong as metal.  My plan with either is to make a pressure treated lumber under frame to attach the panels to.

 

I'm looking for other ideas if anyone has any.  

 

Not the current one,  but sort of the idea 

I think I would do your idea of treated lumber frames and cover them with clear, corrugated fiberglass panels. When going "Out" from the basement- and the outer doors closed- there would be natural light on the steps.

I assume this is a "door" that needs to be lockable? If so, that would make me lean toward something durable like the metal panels. Even if cut, could any edges then be filed smooth and painted/sealed? 

Doesn't this need to be a fairly secure cover? If yes, I'm not sure anything wooden would be quite secure enough.

These are called bulkhead door and can be made with either the side hinges as in the picture you shared or clamshell style with the hinges on the house side. If you want a bit of whimsy you can add details so it looks like a mouth opening, alligator or dragon. 🙂 

Since this is a woodworking forum, I would challenge you to make it entirely out of wood. Support frame with tongue and groove cedar panels. Then seal it with Thompson water seal or a like.

I found a This Old House link that discusses material options that might be helpful.

The first thing I'd investigate is what the local building code requires/allows followed by a consultation asking the same questions with the property insurance provider.  Also will the basement space be used in any fashion as a living quarters?

 

While the natural tendency of any DIY'er is to save money by building themselves, this is one project I'd go commercial.  If it was my property, I'd go with a new set of Bilco doors. Properly maintained, they'll outlive the kids that will be live there.

 

Bilco is the gold standard IMHO for exterior basement egress covers. While not inexpensive, properly installed, they will provide a safe, secure and weather-tite seal. They also will endure nearly any abuse a college age crowd can administer short of an oxy/acetylene torch. If metal doors are not your thing, Bilco also offers a polyethylene model...HERE.

 

My $.05 worth since pennies are nearly extinct now.

4 hours ago, Grandpadave52 said:

The first thing I'd investigate is what the local building code requires/allows followed by a consultation asking the same questions with the property insurance provider.  Also will the basement space be used in any fashion as a living quarters?

 

While the natural tendency of any DIY'er is to save money by building themselves, this is one project I'd go commercial.  If it was my property, I'd go with a new set of Bilco doors. Properly maintained, they'll outlive the kids that will be live there.

 

Bilco is the gold standard IMHO for exterior basement egress covers. While not inexpensive, properly installed, they will provide a safe, secure and weather-tite seal. They also will endure nearly any abuse a college age crowd can administer short of an oxy/acetylene torch. If metal doors are not your thing, Bilco also offers a polyethylene model...HERE.

 

My $.05 worth since pennies are nearly extinct now.

 I agree with the sentiments about using a commercial product in this instance .

With an estimated 300 BILLION pennies in circulation, it may be awhile before there is any "real" shortage.

I'm with Gramps and Wichman on this. Anything BUT steel is prone to problems, the worst one being the ease with which crooks can gain entry. And by all means, check with your insurance supplier first.

6 minutes ago, HARO50 said:

the worst one being the ease with which crooks can gain entry

That actually was one of my first thoughts. Scary movies planted that concern in my head! 

Unfortunately, those same scary movies also plant ideas in law-breakers' heads. That's why both the cover and the actual door to the basement should be as secure as possible.

Keith, I think you'll have to consider snow loads in the build as well.

3 hours ago, DuckSoup said:

Keith, I think you'll have to consider snow loads in the build as well.

yes, especially after the last two weeks

@Grandpadave52 is correct. I had a good experience with a Bilco door. It wasn't cheap 40 years ago.

You describe a cover that is rotted, which was the typical setup in older homes. We had a place with a Bilco door and it was great for protection and security as well as access. I installed it when I was young and stupid. (Not young anymore.) Weather tight it is not.

I our case, we had a set of pt steps down the basement level, where a standard entry door with framing was installed.

Your photo shows a good buildup around the door to prevent runoff down the steps.

Weather and schedule finally cleared up and got it installed this week. Almost there, the edges need to be bent over, but my daughter's brother-in-law has a tool for this. Underneath is a grid of half-lapped pressure treated 2x4 hinged on the edges. Left side is a bit wider than the right so that the metal panel didn't end up at a ridge along the outside and there's an overlap in the middle.

Nice!!

Looks good. I remember my grandfather's just being wood. Painted of course.

11 minutes ago, HandyDan said:

Looks good. I remember my grandfather's just being wood. Painted of course.

Yeah, the old one was wood and very rotted

Nicely done