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Daverimmer 11-23-2010 09:01 AM

I have decided to make a garage door to replace the current old overhanging door. I have looked extensively online for plans or even detailed instructions without success.

I am hoping someone here will either error check my own plan or offer advice...

Using 2x12 diminutional doulglas fir I will rip 2"x3x"9' rails for the top and bottom of each of four panels.
I will rabbett in a notch on one side of each rail for 3/8ths in plywood panels.
On the opposite side of the rabbetted groove on four of the rails, I will cut an overlapping notch so that when the door is closed each panel will rest in the panel next to it.
2x3x22" vertical rails for the ends and center, also notched on one side except for the center which will be notched on both sides.
The vertical and horizontal rails will be ship-lap joined, glued and screwed.
Panels are then inserted and glued in.

Hinges and other hardware attached with bolts etc.

Anything here seem wrong or could be done differently or better?



Daverimmer 11-23-2010 05:14 PM

1 Attachment(s)
Ok no replies thus far so I will document here my own process which hopefully will help someone else.

Here is by plan for the nine foot rails.

I will post my stiles as well. All rails and stiles to be made with two by three Douglas fir.

The door itself will have 4 panels each measuring 22" x 108"'s.

Door size is 88" x 108"

stadry 11-23-2010 06:58 PM

gawdblessya ! most would call the garage door company like i did :yes:

Daverimmer 11-23-2010 07:58 PM

Stiles design
1 Attachment(s)
Stiles design

Attachment 27095

Daverimmer 11-24-2010 01:25 AM

1 Attachment(s)
Ship lap joint and overlapping nose view

Wildie 11-24-2010 06:38 PM

With garage doors, you have to consider weight. If its too heavy it may be difficult if not impossible to get an opener that is capable of lifting it.

Commercially manufactured doors are very competively priced and it may be better to shop around for one of these.

Daverimmer 11-24-2010 06:57 PM

I just don't want to spend the money for a new door. I have all the hardware ready to go from the old door. I have been very concerned about weight. By my calculations my door should top out between 85 and 95 pounds which is in line with the previous, commercially made, wood overhead door.



joetab24 01-04-2011 08:57 PM

did you do it?

johnms123 01-26-2011 02:08 PM

door interest
while attempting to research the same regarding how to build wood roll up door, i came accross your posts. I also was unable to find any informative information though I need view some website of custom wood garage rollup doors that gave me ideas. i have a existing mdf and wood commercial doors which needed to be replaced many, many years ago. I was going to try and duplicate the way they are made. I was thinking about using cypress. it is relatively light and stands up to the elements. going to stain and seal them also. planning on mortise / tendons the rails and stiles and either try to locate cypress plywood for panels our see if i could you T&G cypress flooring in lieu of panels. from what i can see from pricing of custom wood doors, i think i can source material less expensively and re-use my existing rollers, hinges and hardware. can you update me on the status of your project? thanks, john

rditz 01-26-2011 02:50 PM


You will have a roll-up door spring, right?? if your doors are too heavy, get a bigger spring and tension accordingly

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