Metal Dutch door options -- safety?

[Libby2563]

My horses aren’t bad chewers but even the occasional nibble has done a number on my wooden Dutch doors and the paint. I’m considering replacing them with metal doors. There are only three doors so the cost wouldn’t be too terrible.

The question is, what is the safest construction? I’m mainly concerned about the safety of the lower half of the door, specifically a horse not being able to kick through the inner layer of metal and getting a leg caught. I’ve been contacting some builders/suppliers and there seem to be a few different options:

Metal framing and crossbucks that I would fill with my own lumber, so all corners and edges would be metal for durability but the flat areas would be wood–seems like a safe option.

Metal sheathing on top of plywood or similar solid core–also seems safe because the horse can’t punch through the metal and get a foot caught in a hollow space between two sheets of metal.

Hollow aluminum beadboard–this seems like a safety issue to me. I picture a horse kicking through the inner layer of beadboard because there is nothing behind it to stop the hoof, and getting caught inside the door. Is this a real concern or am I underestimating the strength of this material? This is the most cost-effective option so far but I just don’t feel comfortable with it.

Any opinions on this? Am I overthinking it?

[2DogsFarm]

I have your 2nd option - wood sheathed in metal.

Doors are open 24/7 to allow horses free access to stalls.
After 11yrs & 2 sets of geldings noone has kicked a door whether they are stalled (infrequently for shoer or vet or even more rarely for weather) or left latched open.

[Highflyer]

Do you need to replace the whole door/ have the whole door be metal or can you just put metal flashing across the top? Our doors are solid oak with metal (I think it’s steel) across the top of the door, and they’re over a hundred years old.

[Libby2563]

[QUOTE=Highflyer;8306787]
Do you need to replace the whole door/ have the whole door be metal or can you just put metal flashing across the top? Our doors are solid oak with metal (I think it’s steel) across the top of the door, and they’re over a hundred years old.[/QUOTE]

There is already a metal chew strip across the top of the bottom half, but they have also nibbled on the sides of the top half and the crossbuck on the bottom half. I think it would be difficult to add chew strips everywhere they need to be while still allowing the doors to close.

I envy your oak. My kickboards are oak and they are very sturdy, but these doors are pine and they show every dent and nick.

[Bluey]

We have plate steel on a steel frame and no horse has ever kicked thru that.

If you get the right steel gauge and weld it where it doesn’t come loose from a kick, why not?

If you want airflow thru the bottom of the door, the new cross hatch 1/4 steel welded metal types seem to work well for that:

[Libby2563]

[QUOTE=Bluey;8306981]
We have plate steel on a steel frame and no horse has ever kicked thru that.

If you get the right steel gauge and weld it where it doesn’t come loose from a kick, why not?[/QUOTE]

Thanks! What would you consider the “right” gauge steel?

My concern is that a double layer of aluminum with airspace in between would not be sturdy enough.

[Bluey]

[QUOTE=Libby2563;8307359]
Thanks! What would you consider the “right” gauge steel?

My concern is that a double layer of aluminum with airspace in between would not be sturdy enough.[/QUOTE]

Why would you want aluminum for a solid horse stall door and why double?

If you use metal, steel is generally used for that, one sheet is enough.

The welder that makes those will know what sheet metal to use.

We make our own, one neighbor is a professional welder and he gets the material.
Will have to ask him next time I see him which it is we used for stall doors and cattle pens where solid.

Some of those are now a good 25+ years old and still fine, no horse ever damaged them or itself on them.

Other works also, like sheeted wood, then you may use aluminum, or straight wood, some even use plastic sheeting or plastic planks in place of wood or metal.

You are right, wherever you have wood where horses have access to it, they will scratch it and get splinters and some do beaver impressions on it.

Since you only are talking about three doors, how about asking for bids from some companies that produce commercial stalls?

MD Barns has metal clad wood, Lucas, Ramm.
Google and you will find many, some close to you, some you really like.

They could make you some any way you want them made.

[Libby2563]

[QUOTE=Bluey;8307375]
Why would you want aluminum for a solid horse stall door and why double?[/QUOTE]

Well, I don’t think I do…but one of the suppliers I have contacted uses that, which is why I’m asking. Actually on more careful reading/looking I think it might just be a single sheet of aluminum.

Thanks for the other suggestions! Already been in touch with Lucas and Ramm but I’m going to check out MD Barns now…

[Simkie]

I have the plyco doors and they’re steel. Very heavy. A horse won’t kick through. Have you talked to those guys?

[Libby2563]

[QUOTE=Simkie;8307761]
I have the plyco doors and they’re steel. Very heavy. A horse won’t kick through. Have you talked to those guys?[/QUOTE]

Great, thanks for the recommendation! I have emailed them but haven’t heard back. Will try a phone call soon.