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TREX decking gate construction
I would use a steel skeleton made of 1" sq. tubing. Properly designed and built it would last a lifetime and not sag or twist like wood will. And you can attach sturdy hinges and hardware with carriage bolts instad of into the Trex. This will also free you up designwise to add an arch or other feature not easiy or practical to make from wood or Trex.
On a different note, are you sure you rreally want to use Trex? My local yard used to carry up until a few years ago. They had complaints of sagging in the summer and shrinking and breaking in the winter. The only cure for sag was to double on spacing of the joists or go every 12". There are a lot of other types of composites that I researched for a job (I didn't get) through another local yard that caters to higher-end users. Trex in their in-store display was at the very low end, and was used more or less to show customers this isn't what you want to buy. There are some products that cost about twice the cost of Trex but are well worth it in final fit-and-finish---some had the look of furniture grade teak or walnut, but were synthetic.
And keep in mind Trex is a blend of wood fibers and polyproplene (recycled milk jugs) so the i will require cleaning and staining just like regular wood otherwise it will look dull and oxidized. And be sure to use the right screws otherwise the Trex will extrude up and around the heads looking quite nasty.
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TREX decking gate construction
KW: I'm a long way from home, but if I remember the name of the yard I'll be sure and let you know.
Have you thought of using a solid (extruded) vynil or an extruded aluminum with a baked-on finish? Home Depot has a commercial-grade railing system that is very nice and about two or three times the cost of crappy "wrought iron" entry-level stuff.
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TREX decking gate construction
I agree that powdercoating isn't the way to go; it tends to peel and scale off. To match your bronze look, yu might want to look at a spray paint Home Depot or Lowes has that is beleive is caled "Hammerite" which has the old look of hammered metal with copper or goldish flakes in it simialr to what was used back in the 30-40's. By the looks of it it probabaly goes on thick to get the appearance so it may hold up well. Another choice would be appliance epoxy, or epoxy in general.
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TREX decking gate construction
Peters: the 20 degrees difference--is that soak due to ambient or sun radiation? Either way, 20 degrees in this application can't be all that much? Real-world, wouldn't the surface temp. alone due to sun soak cause it to warp or at the least soften it to the point it loses rigidity? Polyprop. v. Polyeth.: what am I thinking of? Sheeting goods? What else is made from it?
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