ONE PIECE, DECORATOR
HOW TO BUILD A
BEAUTIFUL ONE PIECE
GARAGE DOOR USING
AMERICAN SERIES HARDWARE
|Note: The One piece garage door opening in this example is to be 16' X 7'. Finished garage door is to be 1" narrower than the opening. Frame is to be 1 1/2" narrower than opening. Frame height is to be the same height as the opening. Important: keep two of the 2" x 4" frame members four inches longer than the rest.|
Step 1. Precut 2" x 4 " frame members to desired length. The MATERIAL SCHEDULE for this sample 16' door is to be 2" X 4" lumber.
Step 2. Pre-notch the top and bottom frame rails to the exact same size of the 2" X 4" framing members. This means a total of four notches cut at each end of your top and bottom 2" X 4" x 16' rails.
Step 3. Lay out frame members on a work table or flat surface.
Note: All 2" x 4" frame members need to be on edge except for the two siderails marked (a). Place these siderails flat and fit them into the notches of the top and bottom rails. As mentioned in opening note at the beginning of this discussion, there were two pieces that needed to be longer than all other frame members. These siderails (a) are the pieces that interlock into the 16' top and bottom frame rail end notches. It will most likely be required to trim each siderail (a), so they are flush with the top and bottom 16' frame rails.
Step 4. Nail frame members together.
Step 4a. (Optional) For added support and strength an additional " V " brace can be installed as shown in the illustration below. The recommended material is usually two 1" X 4" x required length.
Step 5. Lay precut plywood panels on the completed frame. They will overhang on each end of the door by 1/2". Door width can be trimmed down if so desired.
Step 5a.The illustration below shows a corner view of the interlocked garage door frame with top plywood facing on top.
Step 6. Nail plywood panels to frame.|
Plywood can be set up 1-1/4" at the top if headroom allows and should be set back 1/4" at the bottom to prevent splintering.
Step 7. Add trim and bottom weatherstrip as desired. Keep door balanced top and bottom.
(Truss Rods should also be applied if the door is wider than 12', If desired side weatherstrip and locking hardware can also be installed)
Paint door on all exposed sides and edges. Front and Back!
Note: IF DESIRED, OTHER FACE MATERIALS, SUCH AS SIDING, TONQUE AND GROOVE, SHIP-LAP, FIBERGLASS OR ALUMINUM MAY BE USED IN PLACE OF PLYWOOD.
MATERIAL SCHEDULE FOR ONE PIECE WOOD DOOR.
For best results all rails and stiles should be Contruction grade Douglas Fir or better.
NOTE: Lengths may be varied to fit local market's unusual lumber dimensions. 2" X 3" lumber may be used in place of 2" X 4". Adjust calculated weight accordingly.
For existing openings there are 6 required measurements.
This helps to insure that the door fits into the opening properly.