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Old 04-15-2012, 07:46 PM   #1
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Replace garage door panels?


My garage door falling apart, literally at the seems and needs to be replaced. The opener, track, and hinges are all in good condition, it's just the door panels that are in disrepair. I was measuring the panels and each are 21" tall (4 total making the entire door 7' tall) by 8' wide and 1' 1/2" thick. I was thinking about replacing just the panels by building them myself using 2x4's and plywood inserts, then staining the wood and sealing it up with a couple coats of a satin epoxy.

It wood look very much like these doors, maybe with the top row being glass instead of plywood.

For those who are going to warn me about how dangerous working on garage doors is, thanks I am very much aware.

I was wondering if anyone has made their own panels successfully, or has any advice on whether this is feasible.

Thanks.

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Old 04-15-2012, 07:56 PM   #2
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Replace garage door panels?


Total waste of time and money.
Just go buy new doors.

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Old 04-15-2012, 08:10 PM   #3
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Replace garage door panels?


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Total waste of time and money.
Just go buy new doors.
I would disagree, I calculated the total materials to be around $100. A new white steel door is around $400, and anything that even resembles wood would cost near $900 dollars.
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Old 04-15-2012, 08:15 PM   #4
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Replace garage door panels?


Square aluminum tubing as a frame.
Rigid insulation to infill that frame.
Skin with FRP.
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Old 04-15-2012, 08:44 PM   #5
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Replace garage door panels?


What you suggest will not come out looking like those doors. Using framing lumber and expecting finish results is futile. Not to mention the time that will be used.
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Old 04-15-2012, 08:50 PM   #6
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Replace garage door panels?


Have you considered the weight difference?
Will the current opener be able to handle the weight?
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Old 04-15-2012, 09:49 PM   #7
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Have you considered the weight difference?
Will the current opener be able to handle the weight?
From what I understand the weight of the door is offset by the torsion spring, making it easy for the opener to lift. a well torsioned door should be able to be lifted by hand, which really makes the spring the central issue with weight. The spring is rated for a couple hundred pounds, but I have not done any calcs to see how much all that wood would weigh yet.
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Old 04-16-2012, 07:48 AM   #8
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Replace garage door panels?


Yes. I built replacement panels regularly for a refuse company who's drivers would bust up doors. Use exterior rated plywood for the panels. Dowel the joints with some good strong stock. Use waterproof glue. Set the panels in a bed of sealant. The top and bottom rails of the panels have a half lap that closes the seam when the door is closed. Make sure that is duplicated properly so the door doesn't bind. Avoid spruce for the frames. Try to use fir or pine. If they're kept properly painted, they'll last a long time.
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Old 04-17-2012, 09:23 AM   #9
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Yes. I built replacement panels regularly for a refuse company who's drivers would bust up doors. Use exterior rated plywood for the panels. Dowel the joints with some good strong stock. Use waterproof glue. Set the panels in a bed of sealant. The top and bottom rails of the panels have a half lap that closes the seam when the door is closed. Make sure that is duplicated properly so the door doesn't bind. Avoid spruce for the frames. Try to use fir or pine. If they're kept properly painted, they'll last a long time.
Thanks for the great advice, I also noticed the lap between each panel that kept them from binding, which I will make sure to recreate on the new panels. Would you still recommend pine for a stained surface? I really want to keep the wood with a red colored semi-transparent stain if possible.
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Old 04-18-2012, 12:18 PM   #10
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Replace garage door panels?


I can't say how a stain would work. Everything I made was painted. I would still avoid spruce.
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Old 04-18-2012, 05:53 PM   #11
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Replace garage door panels?


We used three different springs for different weight doors......

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Old 04-19-2012, 01:06 PM   #12
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Replace garage door panels?


If you build your new panels to match the old, then the weight should be approximately the same. You should only need some minor adjustment.
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Old 07-08-2012, 04:38 AM   #13
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Replace garage door panels?


Hello, I noticed this thread is a little old, but instead of making a new thread, I wanted to know if you ever made the doors or not.. If so, how did they turn out? Any pictures?
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Old 07-08-2012, 08:07 AM   #14
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I wonder what happened,too.

That is some very advanced wood working---the stile and rail cutters--and panel raising bits alone would cost nearly $200---

$100 for the wood? Sure would like to see before and after pictures and a list of actual costs.

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