Building an 80 Ft Long Shipping Container with an Insulated Garage Door & More! | The Container Guy

Follow along in this video as we connect two 40-foot shipping containers together end to end!

We already showed you how we connected two 20-foot containers to make a 40’, and how to connect two 40-ft containers side-by-side to make a double wide shipping container, but now we want to show you what an 80’ double long container will look like!

For this modification, we will be removing the container doors, installing strut channels, a man door on either side of the double long container, an overhead garage door on the side, and then connecting the two sea cans using our end-to-end kit. And we did this whole modification without having to weld anything!

Purchase Container Modification World Products Featured in The Video

Connecting Two 40-Foot Shipping Containers to Create an 80-Foot Space

In this walkthrough, Channing McCorriston, The Container Guy, demonstrates how two 40-foot shipping containers can be connected end to end to create a fully functional 80-foot structure.

Using a custom engineered end-to-end connection kit, the project maintains structural integrity, insulation performance, and usability while dramatically increasing interior space.

Preparing the Containers

The process begins by removing the standard container doors. Hinge pins are cut using an angle grinder, freeing the doors while leaving lock rods attached for safer handling.

Once removed, the end walls are prepared for framing and connection. Proper prep work ensures the containers can align tightly without unnecessary grinding or modification.

Interior Strut Channel Framework

Inside each container, strut channels are installed every fourth corrugation.

These are positioned in the insulated configuration, leaving roughly two inches of space behind them for spray foam insulation. This approach accomplishes two goals:

• Creates a continuous vapor barrier

• Provides mounting points for electricians and plumbers

With strut channels in place, panels, conduit, piping, and fixtures can be installed cleanly without compromising insulation.

Installing the Insulated Overhead Door

A commercial insulated overhead door is installed at one end of the new 80-foot structure.

Unlike shallow roll-up door frames, this custom frame is deeper to allow spray foam insulation behind it. The design includes a center mounting flange for overhead spring hardware and is engineered to accommodate existing weld seams and corrugation profiles.

By designing the frame around the container’s geometry, the need for excessive grinding is minimized.

Spray Foam and Vapor Control

The entire interior and underside of the containers are spray foamed with two inches of closed cell insulation.

This creates an effective thermal envelope and vapor barrier. Underside insulation covers cross members and the gooseneck cavity, protecting the floor system and reducing thermal bridging.

Interior and exterior flashing kits are installed to seal joints and prevent water intrusion while retaining spray foam integrity.

High Capacity Bridge Fittings

The core of the system is the high capacity bridge fitting kit.

These fittings connect the containers structurally through the corner castings and are rated for 65,000 pounds. Magnetic and threaded locking mechanisms assist with alignment, and slotted holes allow minor adjustments during installation.

The connection is fully removable. Four bolts allow the containers to be separated for relocation or transport.

This makes the system modular rather than permanent.

Structural Reinforcement and Flashing

Laser cut headers, side frames, and footers are designed to match container corrugations precisely.

Return flanges and pre-drilled holes allow additional reinforcement or door installations if needed. Minor revisions during installation, such as notching flashing to close gaps, ensure a tight final fit.

Leveling and blocking the containers before connection is emphasized as critical for proper alignment.

Electrical Installation

The completed 80-foot structure includes:

• Electric heaters with dedicated shutoff switches

• Multiple junction boxes

• Heavy conduit runs

• Numerous outlets for appliances and equipment

An exterior junction box simplifies outside connections and cable management.

The interior layout is designed to support fridges, freezers, and other electrical loads efficiently.

Final Outcome

By combining engineered bridge fittings, spray foam insulation, custom flashing kits, and a modified overhead door frame, this project transforms two standard 40-foot containers into a single 80-foot insulated structure.

The end-to-end connection kit maintains structural strength while preserving vapor control and usability. Because the system is modular and removable, it offers flexibility for transport and future reconfiguration.

This approach balances durability, insulation performance, and installation efficiency, making it a practical solution for customers who need extended container space without sacrificing structural integrity.