GARAGE DOOR V4 — ASSEMBLY MANUAL REVIEW
Reviewed 08 October 2026. All project dimensions below are in cm.

SCOPE
The model is an outward-opening pair. Viewed from outside, RIGHT is active and opens first. Reuse sound existing frame members and joints. The half-lap drawings describe conditional replacement pieces, not an instruction to cut new notches in an intact existing frame. Existing wood, hinges, mounting patterns, frame joints and jambs remain uninspected. The manual can accurately teach the geometry and sequence while identifying the exact field entries still needed to release cutting and hanging.

CRITICAL SEQUENCE POINTS
1. Select hardware and mark all its real holes before closing either inaccessible mounting area. Fit full-depth backing before foam; accommodate any hardware that needs access behind the inner lining before closing it.
2. Weigh each built leaf, add the measured mass of its remaining hardware/cover/seals, and confirm the complete hinge/jamb/fastener system before a dry hang. The older construction-review.txt records weight too late; the newer A08 sequence is correct.
3. Keep bonding faces compatible with their chosen adhesive. Do not instruct the user to prime every bonding face and then apply an adhesive that requires a porous unpainted substrate.
4. Fit foam flush after allowing for actual adhesive bedding. A nominal 3.81 cm foam sheet in a 3.81 cm cavity plus a thick adhesive bead can stand proud and bow the 0.508 cm liner.
5. Use the actual gasket to choose the center spacer. The illustrated 0.3 cm is compressed working clearance, not the free thickness of a purchased tape.
6. Confirm actual closed alignment before final center-cover/end cuts and final seal placement. Mark the middle trim across both leaves from one common level datum. Cutting both at the same height from their own bottoms will not align them if the installed leaves differ in height.

RECOMMENDED ILLUSTRATED STEP TEXT

01 — Check the opening and label both doors
Measure the opening at its top, middle and bottom; measure its height at both sides and center, both diagonals, and the highest floor point along the full outward swing. Record each existing leaf's width, height and thickness. Mark OUTSIDE, TOP, HINGE EDGE and MEETING EDGE before removing anything. Support and restrain each leaf before releasing hinges; work one leaf at a time with a helper and a suitable lifting support.
CHECK: Actual dimensions and the selected hinge/sweep clearances are recorded. The 257 × 216 cm opening and 127.565 × 213.865 cm leaves remain reference values until checked.
ILLUSTRATION: Closed front elevation, two diagonal arrows, LEFT/RIGHT labels, floor sweep arc.

02 — Expose, inspect and repair the frame
Lay the door on a flat supported bench. Remove the old skin as needed to inspect joints, timber and existing bracing. Retain sound members and sound joints. For replacement framing, use two F1 uprights and three F2 full-width rails per leaf. Do not alter an intact frame merely to match the drawing.
CHECK: No decayed or split fixing zones, loose joints or uncorrected twist remain. The joint and anti-sag connection method is selected before the skins hide it.
ILLUSTRATION: One open frame, retained pieces in neutral color and one optional replacement in accent color. Label replacement-only.

03 — Match the replacement half-laps, if needed
On the replacement F1 stiles, remove the OUTSIDE half at each rail crossing. On each F2 rail end, remove the INSIDE half. The two remaining halves overlap and finish flush. Nominal overlap is 8.89 cm; depth is half the measured timber thickness, nominally 1.905 cm. Rail blanks are 127.565 cm long including the laps; the 109.785 cm opening between stiles is not the rail cut length. Fit all joints dry, clamp the frame square and flat, then use the confirmed joint bonding and mechanical fixing detail.
CHECK: All faces are flush, both diagonals match, and corners are square. Joint fixing sizes, number, edge distances and racking support are confirmed for the actual wood and finished leaf load; generic end-grain screws are not that specification.
ILLUSTRATION: Exploded complementary notch with OUTSIDE/INSIDE faces marked and 8.89 / 1.905 / 3.81 cm callouts.

04 — Mark hardware and add its backing
Lay the actual hinge, bolt, handle and latch templates on the frame. Mark every hole and the chosen hinge pivot. Every load-bearing hole must enter sound timber or a specifically fitted solid block. If a strap extends across a cavity, add full-depth backing for its actual holes before fitting insulation. Complete any nuts, plates or preparations that will become inaccessible. Photograph the open frame and transfer timber outlines to the skin faces.
CHECK: No hinge, latch, bolt or hold-open anchor relies on plywood or foam alone. Hardware installation instructions, screw/bolt size and count, embedment, pilot holes, edge distances, hinge locations and jamb anchors are recorded.
ILLUSTRATION: Strap with its actual-template area marked, solid timber under all holes, a crossed-out hole over foam. Do not dimension a fictional purchased hinge.

05 — Dry-fit the outside plywood and supported seam
Use P1 with P2 on each leaf. Mirror the two layouts so every narrow strip is at the MEETING edge. Strip width = actual leaf width − usable main-sheet width − selected seam gap. The current reference is 127.565 − 121.92 − 0.32 = 5.325 cm. Both edges of the seam must sit on the full-height meeting stile. Check the inside P3/P4 layout the same way.
CHECK: The main sheet bears 3.245 cm on the meeting stile in the model, followed by the 0.32 cm seam and 5.325 cm strip. The joint lies within the 7.5 cm meeting trim. Measure actual sheets before ripping the strips.
ILLUSTRATION: Outside view of pair, seams mirrored inward, detail across 8.89 cm meeting stile. Mark BOTH EDGES ON WOOD.

06 — Attach the outer skin on the flat frame
Prepare the plywood edges and compatible bonding faces. Keep the frame clamped flat and square. Fix the main panel and matching strip using the selected panel-to-frame bonding and fastener schedule, with each seam edge fixed to timber. Keep the selected movement gap open; do not fill it with rigid filler. Preserve a flat outer face while the adhesive cures. Turn the supported leaf with help only after the selected system permits handling.
CHECK: Perimeter and joint fasteners are over timber; the skin is flat; seam spacing remains; the frame has not twisted. The exterior plywood's exposure grade is verified. Adhesive cure/handling requirements are met before flipping.
ILLUSTRATION: Exterior skin over frame, fixing zones shown as lines rather than an invented screw count or spacing.

07 — Fit the insulation flush
With the exterior face down on protected flat supports, measure each finished cavity after repairs and blocking. Trim I1 to fit; the unblocked reference is 109.485 × 93.2975 × 3.81 cm, two inserts per leaf. Dry-fit before applying the selected foam-compatible adhesive. Allow for the actual adhesive bed so the foam finishes level with the timber. Keep the assembly flat and retain the foam as the adhesive manufacturer requires during cure.
CHECK: No proud foam, forced skin, obstructed hardware or unplanned void behind hardware. Foam type, facing, adhesive compatibility, required covering and cure instructions are confirmed for this assembly. The 0.508 cm lining is not assumed to be a rated thermal/fire barrier.
ILLUSTRATION: Open inside face with two blue inserts and a straightedge across timber/foam; enlarged section shows both flush.

08 — Fit the thin inside lining
Fit P3 and P4 with the seam on the same physical meeting stile. Transfer timber lines from the recorded frame, keep the liner flat, and use the selected fixing/adhesive detail. Fix into timber; do not use the foam to hold screws. Set fastener heads flush without crushing the thin veneer or deeply countersinking the 0.508 cm sheet. Any required inside-access hardware work must already be complete.
CHECK: No exposed screw tips, proud heads, split edges or liner bulges. Fastener length allows the chosen timber embedment after passing through 0.508 cm of lining. Let the assembly cure on flat supports as required.
ILLUSTRATION: P3/P4 lowered onto open frame, same meeting-edge seam; flush head versus crushed veneer close-up.

09 — Fit the decorative trim and finish the wood
Dry-fit two T1 vertical trims and three T2 horizontal trims per leaf. Horizontal pieces butt between the verticals. Transfer one common middle-rail level across the supported closed pair, then install the trim. At the meeting seam, fasten through the strip side into the stile; avoid a rigid glue bridge across both plywood edges. Protect hidden nonbonding surfaces, plywood end grain, all exposed faces, top, bottom and side edges with the selected exterior finish. Refinish every later cut or drilled recess.
CHECK: Rows align across the pair. Trim hides the skin seams, and the leaves remain separate. No trim or hard filler locks the panel movement seam. Bonding areas remain compatible with their adhesive, and coatings have cured before seals are applied.
ILLUSTRATION: Two finished closed leaves and level datum; trim pieces highlighted; inset showing one-sided seam cover attachment.

10 — Weigh, confirm the hinges and hang with support
Record the finished mass of each leaf and the measured mass of any remaining fittings. Confirm hinge model, actual door size/mass, pivot, mounting pattern, joint capacity and structural jamb anchors as a complete installation. Support each leaf at the verified gaps while fixing its hinges to their templates. Keep the hinge axes aligned and check each leaf over its full intended swing with the support/control in place. Do not release an unsecured leaf.
CHECK: Hardware and frame/jamb fixing details are complete before hanging. Neither the three-hinge illustration nor the approximately 41 kg base-material estimate is a capacity rating. Confirm clearances after hanging; reseal any fresh trimming.
ILLUSTRATION: Supported leaf, helper/lifting aid, actual hinge axes and gaps. If numbers shown: 0.635 cm sides/top, 0.6 cm center, 1.5 cm bottom, all labeled provisional.

11 — Fit the right-only center cover and seals
Close and secure the LEFT leaf, then close the RIGHT. Fit C2 and C1 to the RIGHT meeting stile only. The nominal cover has 3 cm of support on the right, crosses the 0.6 cm gap and overlaps the left by 2.4 cm. Mount S1 on the back of the overlap so it seals against the left trim. Set spacer thickness from the selected gasket's working compression. Cut the ends to meet the actual head and bottom seals, then fit perimeter seals and sweeps on clean, dry, cured surfaces.
CHECK: Cover fasteners pass through the 0.6 cm cover, actual spacer, 0.6 cm trim and exterior skin into the RIGHT solid stile; none land in the center air gap or enter the left leaf. The 2.2 cm gasket width and 0.3 cm compressed depth are reference geometry. The latch closes without crushing the gasket or forcing the doors out of plane.
ILLUSTRATION: Top section with 3 + 0.6 + 2.4 = 6 cm chain, screw axis inside right support, arrows showing right opens first.

12 — Fit restraints and check the complete pair
Finish the inactive leaf's top/bottom bolts and keepers, the active latch, both handles and the hold-open devices using their actual templates and solid backing. Open the right door first, then release/open the left. Close and bolt the left first; close and latch the right last. Test the complete intended swing under control. Check for rubbing, binding, loose fixings, seal discontinuities and unwanted movement at the frame or jamb.
CHECK: Record actual final gaps, masses, hinge/fastener models and date. Recheck fasteners, alignment, coatings and seals after initial use and seasonally using the chosen product guidance.
ILLUSTRATION: Two mini views for opening order and closing order, plus six completion boxes.

HARDWARE AND FASTENER FILL-IN BOX — MUST NOT BE INVENTED
For each fixing group (frame joint; outer skin; inner lining; trim; hinge on leaf; hinge on jamb; latch/bolt; center cover; hold-open): product/model ___ ; screw/bolt diameter ___ ; length ___ ; number/spacing ___ ; pilot/clearance hole ___ ; edge distance ___ ; timber embedment/anchor substrate ___ ; backing/access ___ .
For each leaf: measured width ___ cm ; height ___ cm ; finished weighed mass ___ kg ; remaining fittings ___ kg ; hinge suitability verified by product/supplier/installer ___ .
For adhesives/finish: substrate and foam facing ___ ; compatible product ___ ; bonding-face preparation ___ ; assembly/handling time ___ ; full cure ___ ; application conditions ___ .
For center seal: actual profile ___ ; free thickness ___ cm ; recommended compressed gap ___ cm ; spacer thickness ___ cm ; fitted cover length ___ cm .

USEFUL FASTENER GEOMETRY — NOT A STRENGTH SPECIFICATION
Let e be the selected required embedment into solid timber, in cm; washers, countersinks and actual hardware thickness are extra and must be included.
Inside lining screw path: 0.508 + e.
Outer skin screw path: 1.190625 + e.
Trim screw path: 0.6 + 1.190625 + e = 1.790625 + e.
Center cover screw path: 0.6 + actual spacer + 0.6 + 1.190625 + e; at the illustrated 0.3 cm spacer this is 2.690625 + e.
These equations check reach to wood only. They do not select diameter, spacing, capacity or a safe standard screw length. Check actual stack, fastener tips, opposing fittings and residual timber thickness.

SOURCE LIMITS
The precise geometry comes from the existing CAD. Construction principles are supported by the manufacturer sources in assembly-primary-sources.json. These sources do not certify this site-built door, hinge system, structural skin/foam bond, weather performance or 0.508 cm lining.
