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A garage door panel is made up of virtually the same parts as a regular person door. It consists of rails (top and bottom of panel), stiles ( left side, right side and multiple stiles in between depending on the number of panels in the door) and the panels (raised or flat).
First, measure the panel to be replaced, width and height. Measure the rails and styles and panels. Write all the information down.
Using a good exterior grade lumber (typically fir) the straighter the grain the more stable the door panel will be. Cut rails to length and then stiles to fit between the rails (allow extra length on the stiles for a tenon on both ends to go into a mortise on the rails.
Cut a groove or dado in the rails and stiles to receive the panels. Cut the mortises in the rails. Cut the tenons on the stiles. Dry-fit the joints and adjust as needed. Measure for the panels during the dry-fitting process.
Cut the panels to the correct size leaving them about 1/8"- 1/4" short in width and height. Flat panels can be made of a good exterior grade plywood. Raised panels can be made using the same fir used for rails and styles glued together to make the necessary width and height. Raising the panel can be done on a table saw or with a router.
Once the panels are cut, dry-fit all the pieces for the door panel. Disassemble and apply a good exterior wood glue to surfaces of the tenons only. DO NOT APPLY GLUE TO THE PANELS. Assemble the door and clamp overnight. Remove clamps, clean-up excess glue, prime with a good exterior oil-based primer (all sides and edges). Sand lightly and apply 2 coats of either oil or acrylic latex exterior finish paint. For stained doors, follow the same procedure with exterior stain and a good exterior "Spar" varnish or urethane.

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15y ago

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