Replies

1. 
   scrumseeker | Oct 24, 2006 02:50am | #1

   I have done this both ways, and would definitely recommend applying a design to a flush masonite door over building one from scratch. 

   When building a door from scratch many designs only include two or three door sections,  which are much harder to transition through a garage door track radius than a more common four or five section door.

   The masonite door can be ordered as an insulated door.

   When preparing for this job, make the overlay design up as will be installed.  Than pile it all up on a bathroom scale.  It is important to get a precise weight that you will apply to the door.  You will probably have to add a few pounds for glue, fasteners, finish, etc.

   With this information,  order your insulated masonite door with the springs designed to carry the extra weight you will be adding.  Also,  my garage door dealer will get the track with extended brackets for attaching to the wall.  This allows for the extra thickness of the added material.

   When the door arrive,  assemble the sections on a work table,  apply your overlay,  and cut the joints out between each section (you can cut them on a bevel to help shed water.  Now the door is ready to be installed.

1. 
   woodeye | Oct 24, 2006 04:12am | #2

   thanks how do you handle the window section?

1. 
   Gene_Davis | Oct 24, 2006 05:18am | #3

   I have scratchbuilt garage doors, both all-paneled and with lites in the top panel.

   The panels are easy.  I do them with a core frame of 5/4 pine, a luan skin on the inside, and either a luan, MDO, or grooveless T111 on the face.  Trim is either primo western red cedar or mahogany.

   A multi-line top panel is just a multi-sash with a buildup of thicknesses so that the panel matches the solid ones below.

   I don't hang them, I get my garage door guy to bring out a kit of track, spring, openers, and all the hinge and other hardware. 

2. 
   scrumseeker | Oct 24, 2006 01:44pm | #4

   Well you hadn't mentioned lites.

   In this case, I would build the door from scratch,  just get a knowledgeable door installer to help you with the hardware package.

   Again the weight will be important for proper counterbalance. 

   Try to design the door with 4 or more horizontal sections.  (3 sections will work allright for a 7' high door)

2. 
   Piffin | Oct 24, 2006 02:32pm | #5

   I have done a couple and don't care to. I tend to overbuild which makes it expensive, but also, you really have to focus on weight to balance hardware to it.
   Without specializing in that, it takes a lot of effort and time that I can put to better uses than re-inventing the wheel.

    

    

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