As for making one! Well , i'm not a metal worker. lol But looking at it, if you knew your way around metal and had access to tools like a bender and welder well..... possibilities are endless. lol
Like you said, even the bolted on versions still attract the same issue. The door still cops all the weight, and some of it being the peel-away effect. Door may bend the top portion possibly jeopardising the seal. I've take both my doors off due to an incident and there is NOTHING in them. Some of the earlier GU's had the large door develop cracks. @mudski and a few others have had this issue.
When you say 10-20kg of weight, i'm assuming being strapped to the ladder while i transit??? When climbing it , average person is 70kg+. I know it's only momentary weight, but still.
Chances of damage are probably low, but still can happen. Lucky the doors are relatively cheap. When my big barn door got damaged, i went to wreckers and they let me choose from aroud 50+ white barn doors in their yard. So if it happens, simple bolt off, bolt on ! lol





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