I'm looking to replace my narrow exterior garage door, which is only 24" wide and has seen better days. Instead of ordering a custom door, I'd like to tackle this as a DIY project. I'm considering building a frame, insulating it, and using plywood for the exterior, just like the original door. However, I'm also thinking about making it from solid wood. It really doesn't need to be fancy, and I prefer no windows. I live in a cold area with some moisture, and the current door measures 24" x 80" x 1.75". Fortunately, I have a good workshop to make this happen.
2 Answers
I built a solid frame and panel door for my exterior, and it's held up really well. I used 3" mortise and tenon joints for the rails and stiles, along with wooden jambs that seal tight and avoid any issues. If you want to get more visual inspiration, here's a photo of what I made! [Link to image]
From my experience in a cold climate, I'd suggest checking out steel insulated doors from your local home improvement store. They offer way better insulation than wooden doors, which can be really beneficial. If you still want to build your own, consider using 1" insulation foam sandwiched between 3/8" plywood. You'll need to add 1" inserts for the edges and a sturdy piece for the locking mechanism, perhaps by laminating a couple of pieces of 1/2" plywood. Don’t forget to finish it off with three coats of poly to protect against the elements!
Great tips! I actually got a heater for my garage once, and it's been a game changer. Keeps everything cozy in winter, but summers can get pretty hot! Thanks for the advice!
Nice door! How thick are the panels? Did you use plywood or solid wood for that?