PAGE 1
GARAGE DOOR  /  V4 / FIELD-FIT EDITION
01 / 27
Garage door assembly
An illustrated guide for rebuilding your existing outward-opening pair.
SELECT MATERIALS IN IMPERIAL; CUT IN cm
Outside plywood
Flat timber core
Inside plywood
White trim
15/32 in thick
2×4; actual 1½ × 3½ in
1/5 in thick
Model: 0.236 in thick
Use imperial labels for tools, fasteners and stock. Cuts and workshop marks are in cm. Keep
sound existing framing; replacement half-laps apply only where needed.
Find the next action
Pages
Measure, gather tools and identify parts
2-5
Prepare frame, backing, plywood and insulation
6-13
Fit trim, finish, hang and seal
14-19
Record checks; workshop details; source notes
20-27
Planning basis: 257 × 216 cm opening. The site and hardware must be verified.
01


PAGE 2
GARAGE DOOR  /  ASSEMBLY MANUAL
02 / 27
Before you cut
Record the existing door sizes and opening. All sizes in this manual remain field-fit references.
 LEFT
closes first
RIGHT
opens first
257 cm opening reference
216 cm reference
MEASURE AND WRITE
Opening widths: top / middle / bottom
Opening heights: left / center / right
Both opening diagonals
Existing LEFT: width / height / depth
Existing RIGHT: width / height / depth
Floor high point through the full swing
TOOLS AND WORKSPACE
Tape measure, square, straightedge/level, pencil, clamps, flat supports, drill/driver and bits. A guided saw for
plywood; suitable joint-cutting tools only for replacement frame members. Add sanding/finishing supplies,
eye/hearing/dust protection, and a helper with suitable lifting/support equipment.
CONFIRM THESE BEFORE ASSEMBLY
Material condition: dry, flat timber and sound joints. Record existing braces before opening the leaf; keep
sound reinforcement.
Products: verify the outside plywood is suitable for permanent exterior use; select the foam and its required
protective covering. The 1/5 in liner has no established fire/thermal-barrier rating. [1]
Hardware: obtain the actual hinge, latch and bolt templates, including fastener requirements and access to
any nuts or backing plates.
Bonding and finish: choose compatible products before priming. Coatings on a glue surface may prevent the
required bond. [3, 4]
DIMENSION RULE
If the measured opening, retained frame or required covering differs, revise the cut sizes and weight
calculation together. Equal leaves are an assumption in this model.
Equipment / stock: imperial. Cuts / workshop layout: cm. Verify before cutting.
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PAGE 3
GARAGE DOOR  /  IMPERIAL STOCK + METRIC CUTS
1 / 3
1. Frame and plywood
QTY = total for BOTH doors
Stock in inches / feet. Cut lengths in cm; keep stock widths where stated.
F1
Frame uprights
× 4
2 × 4 timber; actual 1-1/2 × 3-1/2 in
Cut length: 213.865 cm
CUT ONLY IF REPLACING
Keep stock width. Cut length and 3 half-laps.
Keep sound existing members.
F2
Frame cross rails
× 6
2 × 4 timber; actual 1-1/2 × 3-1/2 in
Cut length: 127.565 cm
CUT ONLY IF REPLACING
Keep stock width. Cut full leaf width and 2
end half-laps; retain sound rails.
P1
Outside main panels
× 2
15/32 in exterior plywood; 4 ft wide
Cut length: 213.865 cm
YES - CUT HEIGHT
Shorten to the shown length. Keep the actual
usable stock width.
P2
Outside infill strips
× 2
15/32 in matching exterior plywood
Cut: 213.865 × 5.325 cm
YES - CUT TO SIZE
Cut width and length unless your existing strips
fit. Support on timber.
P3
Inside main panels
× 2
1/5 in inner plywood; 4 ft wide
Cut length: 213.865 cm
YES - CUT HEIGHT
Shorten to the shown length. Keep the actual
usable stock width.
P4
Inside infill strips
× 2
1/5 in matching inner plywood
Cut: 213.865 × 5.325 cm
YES - CUT TO SIZE
Cut width and length unless your existing strips
fit. Support on timber.
Half-lap cuts: 8.89 cm long × 1.905 cm deep for the stated stock. Mark from actual timber. Pictures use separate scales.
Decimal precision is not a cutting tolerance.
03 / 27
ASSEMBLY MANUAL / PARTS REFERENCE / QUANTITIES FOR BOTH DOORS
03


PAGE 4
GARAGE DOOR  /  IMPERIAL STOCK + METRIC CUTS
2 / 3
2. Insulation, trim and joint
QTY = total for BOTH doors
Stock thickness in inches. Cut length × width in cm; seal is length only.
I1
Insulation inserts
× 4
1-1/2 in rigid foam
Cut: 109.485 × 93.298 cm
YES - CUT RECTANGLES
Cut length and width. Fit flush in the actual
frame cavities.
T1
Vertical white trim
× 4
Model thickness: approx. 0.236 in*
Cut: 213.865 × 7.5 cm
YES - CUT TO SIZE
Cut length and width. One at each vertical
edge of each door.
T2
Horizontal white trim
× 6
Model thickness: approx. 0.236 in*
Cut: 112.565 × 7.5 cm
YES - CUT TO SIZE
Cut length and width. Three between the
vertical trims on each door.
C1
White center cover
× 1
Model thickness: approx. 0.236 in*
Cut: 213.865 × 6 cm
YES - CUT AND FIT
Cut length and width; fit both ends. Attach to
the RIGHT door only.
C2
Center-cover spacer
× 1
Model thickness: approx. 0.118 in*
Cut: 213.865 × 3 cm
YES - CUT AND FIT
Cut length and width. Thickness follows the
selected gasket; RIGHT only.
S1
Center rubber seal
× 1
Model section: 0.866 × 0.118 in**
Cut length: 213.865 cm
CUT TO LENGTH ONLY
Choose the seal profile, then cut its length. Do
not cut its width to this model.
*Model thicknesses are not exactly 1/4 in or 1/8 in; measure actual stock. **Seal section is a compressed model, not a
purchase specification. Confirm all cuts on the actual door.
04 / 27
ASSEMBLY MANUAL / PARTS REFERENCE / QUANTITIES FOR BOTH DOORS
04


PAGE 5
GARAGE DOOR  /  IMPERIAL STOCK + METRIC CUTS
3 / 3
3. Hardware and edge seals
QTY = total for BOTH doors
Imperial product sizes. Schematic examples; hardware remains to be selected.
H1
Load-bearing hinges
× 6
Size in inches: to select
NO METAL CUTTING
Three per leaf shown. Confirm rating and
timber backing before mounting.
H2
Door pulls
× 2
Size in inches: to select
NO PART CUTTING
Use factory parts. Drill mounting holes to the
selected template.
H3
Latch arrangement
× 1
Size in inches: to select
NO PART CUTTING
Right active door. Fix to solid timber; fit to the
selected template.
H4
Left-door bolts
× 2
Size in inches: to select
NO PART CUTTING
One top and one bottom on the left leaf. Fit
keepers to sound supports.
H5
Hold-open devices
× 2
Size in inches: to select
NO PART CUTTING
One per leaf. Select and position for the actual
outward swing.
H6
Perimeter seals
× 5 runs
Cuts: head 257; sides 216 cm
YES - CUT TO FIT
Sides: 2 runs. Bottoms: 2 × 127.565 cm
reference. Select profiles; measure final cuts.
Seal lengths are planning runs, not final cuts. Extra blocking, screws, adhesives and coatings depend on the actual frame
and selected products; their quantities are not fixed.
05 / 27
ASSEMBLY MANUAL / PARTS REFERENCE / QUANTITIES FOR BOTH DOORS
05


PAGE 6
GARAGE DOOR  /  ASSEMBLY MANUAL
06 / 27
01
Open and label the existing leaf
Work on one leaf at a time. This drawing shows the reference frame, not an inspection of your existing door.
LEFT / RIGHT
OUTSIDE / INSIDE
TOP / BOTTOM
1
Support the leaf securely before releasing its hinges. Mark its handing, top, hinge
edge and outside face. Photograph hinge positions and measure the original gaps.
2
Lower it onto flat, padded supports. Remove the skins carefully enough to preserve sound
framing, joints and braces.
3
Inspect for decay, splits, loose joints, twist and loose fixings. Mark the members that
actually need repair; keep the others.
CHECK BEFORE CONTINUING
You have recorded the actual frame layout and hardware locations. The leaf is supported flat, and every
proposed repair is identified.
Equipment / stock: imperial. Cuts / workshop layout: cm. Verify before cutting.
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PAGE 7
GARAGE DOOR  /  ASSEMBLY MANUAL
07 / 27
02
Repair and square the frame
For each reference leaf: two uprights and three full-width cross rails. Replacement cuts are conditional.
F1 × 2 per door
F2 × 3 per door
Keep sound existing joints
F1
 F2
1
Lay out the retained or replacement members on a flat bench. For new reference members,
use the complementary half-laps on the next page.
2
Clamp to 127.565 cm wide × 213.865 cm high. Compare both diagonals and adjust the
frame until it is square and flat.
3
Complete the confirmed joint fastening/bonding arrangement. Keep the frame square while
it sets; retain or provide the required racking reinforcement.
FRAME CHECK
Nominal rectangle diagonal: 249.020 cm in both directions. Geometry alone does not define joint strength:
confirm the joint fixings and racking resistance for the actual timber and leaf load. [5]
Equipment / stock: imperial. Cuts / workshop layout: cm. Verify before cutting.
07


PAGE 8
GARAGE DOOR  /  ASSEMBLY MANUAL
08 / 27
02A
Half-lap cuts for replacements
Use this page only when rebuilding frame members. Cut half the actual timber thickness, not blindly to a nominal
value.
F1: NOTCH LOWER EDGES FROM THE LEAF BOTTOM
0 cm
102.4875 cm
204.975 cm
BOTTOM
TOP
213.865 cm full upright length
Cut orientation: remove the outside half of F1 at the crossings and the inside half of F2 at its ends. Each notch is
8.89 cm long × 1.905 cm deep in actual 1½ in thick timber.
Fit: trial-fit one lap before repeating cuts. Broad mating faces meet fully, both door faces finish flush, and the total
frame depth remains 1½ in.
CUTTING CHECK
The F2 rail blank is the full 127.565 cm leaf width. Its ends overlap the uprights; do not shorten it to the
109.785 cm clear space between them.
Replacement-only geometry. Select joint fastening for the actual wood and load.
08
HALF-LAP: FIT THE RAIL INTO THE STILEReplacement members only. Keep sound existing frame joints.
1 BRING THE MATCHING CUTS TOGETHER
F1 stile: remaining half
F2 rail end
8.89 cm overlap
1-1/2 in stock
1.905 cm remaining 2 BOTH FACES FINISH FLUSH
OUTSIDE FACE
INSIDE FACE
1-1/2 in total
8.89 cm overlap
1.905 cm + 1.905 cm = 1-1/2 in
F2 full rail blank: 127.565 cm long.Cut complementary laps to half the actual timber thickness; dry-ﬁt ﬂat before ﬁxing.Section through joint
Stock: imperial • Cuts / marks: cm • V4 model reference • Not full size

PAGE 9
GARAGE DOOR  /  ASSEMBLY MANUAL
09 / 27
03
Prepare hardware backing
Select the actual hardware first. Every loaded fixing needs sound wood behind it.
H1 hinges
H3 latch
H4 bolts
Backing: field-sized
SCHEMATIC: hardware pattern governs the backing
Full-depth backing
within the 1½ in core
Every loaded fixing
engages sound timber
No hole positions or extra-blocking cut sizes are specified by this sketch.
1
Place the real hinge, latch and bolt templates on the frame. Mark the hole centers, edge
clearances and jamb/keeper locations.
2
Align the hardware with suitable rails/stiles or add securely connected full-depth blocking to
its exact pattern. Update the foam cuts and weight allowance.
3
Complete access-dependent fasteners, nuts or backing plates before closing the skins.
Record the selected fixings on page 20.
BEFORE COVERING THE FRAME
All load paths reach solid door framing and a sound structural jamb. Thin plywood and foam are not the hinge
anchorage. The illustration adds example backing; it is not part of the base cut count.
Hardware holes, fastener sizes and blocking joints follow the selected system.
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PAGE 10
GARAGE DOOR  /  ASSEMBLY MANUAL
10 / 27
04
Attach the outside plywood
Keep the frame flat and square. Mirror the two leaves so their narrow strips meet at the center.
P1 × 1 per door
P2 × 1 per door
Outside face up
F1
F2
P1
P2
1
Dry-fit P1: 213.865 × 121.92 cm and the matching P2 strip: 213.865 × 5.325 cm. Use
15/32 in outside plywood.
2
Put the narrow strip at the meeting edge. Keep the reference 0.32 cm seam between the
pieces, with timber beneath both edges; see the next page. [2]
3
Mark the timber lines on the face. Attach the skins with the confirmed wood/substrate
bonding and fastening schedule; keep fixings over timber and recheck square.
BEFORE THE FINAL RIP CUT
Measure the usable sheet width first. Infill width = measured leaf width - usable main-panel width - selected
seam. Protect cut edges, while keeping glue surfaces compatible with the chosen adhesive.
Equipment / stock: imperial. Cuts / workshop layout: cm. Verify before cutting.
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PAGE 11
GARAGE DOOR  /  ASSEMBLY MANUAL
11 / 27
04A
Keep the seam supported
The narrow strip makes up the extra door width. The white meeting trim hides the seam after assembly.
1
Keep the seam over the meeting stile at the location shown. At the model sizes, the main
sheet bears on 3.245 cm of timber and the strip bears on 5.325 cm.
2
Preserve the 0.32 cm movement seam. Avoid rigid wood filler or a continuous rigid glue
bridge across it. Follow the chosen panel and weather-detail instructions. [2]
3
Later, fix the 7.5 cm meeting trim through the strip side into the stile. Its opposite edge
covers the main sheet while allowing the joint to move.
REPEAT ON THE INSIDE
Apply the same supported-seam layout to P3/P4 on the inside. The shown exterior trim is the seam cover; the
thin interior lining has no added cover strip in the base part list.
Equipment / stock: imperial. Cuts / workshop layout: cm. Verify before cutting.
11
PLYWOOD: SUPPORT THE SEAM ON TIMBERRepresentative left meeting stile shown. Mirror this detail for the right door.
F1 • SOLID MEETING STILE
Main panelcontinues
7.5 cm trim cut width
1.855 cm overlap on main
3.245 cm bearing5.325 cm inﬁll
3-1/2 in solid timber face
0.32 cm movement seamKeep the gap open.
THE OUTSIDE LAYERS
T1 Trim: approx. 0.236 in thick
P1 Main plywood: 15/32 in thick
P2 Matching 15/32 in inﬁll
Fix trim through the inﬁll sideinto the solid timber.
Do not rigidly glue the trimacross both edges of the seam.
Recalculate inﬁll width from the actualusable width of your main plywood sheet.
OUTSIDE
Stock: imperial • Cuts / marks: cm • V4 model reference • Not full sizeT op section

PAGE 12
GARAGE DOOR  /  ASSEMBLY MANUAL
12 / 27
05
Fit the insulation inside
Turn only after the outer-skin bonding system permits handling. Set the exterior face down on padded, flat
supports.
I1 × 2 per door
Inside face up
1½ in core
I1
1
Measure the actual cavities after repairs and hardware backing. Cut each unblocked
reference insert to 109.485 × 93.298 cm from 1½ in foam; two per leaf.
2
Cut and trial-fit each insert without forcing it. Allow for adhesive bedding so the foam
finishes flush with, or below, the frame plane and cannot bow the inner skin.
3
Use adhesive approved for the exact foam/facing and substrates. Follow its application,
retention and full-cure instructions; keep the assembly supported flat. [3]
BEFORE CLOSING THE INSIDE
A straightedge across the frame does not rock on proud foam. Hardware fixings remain accessible as
required. Verify the selected foam covering requirements before fitting the 1/5 in lining.
Equipment / stock: imperial. Cuts / workshop layout: cm. Verify before cutting.
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PAGE 13
GARAGE DOOR  /  ASSEMBLY MANUAL
13 / 27
06
Close the inside face
Use the thinner sheet as an interior lining. Keep the narrow strip on the meeting stile.
P3 × 1 per door
P4 × 1 per door
1/5 in lining
 P3
P4
1
Dry-fit P3: 213.865 × 121.92 cm and P4: 213.865 × 5.325 cm. Preserve the supported
seam just as on the outside.
2
Transfer the rail, stile and backing lines to the lining. Attach using the confirmed fixing
schedule into wood; seat the heads without crushing or pulling through the thin sheet.
3
Support flat for the required adhesive cure. Check the diagonal, face flatness, exposed
edges and all hardware access before proceeding.
LINING CHECK
The lining does not become a structural hinge backing, nor a verified protective covering for every foam
product, merely because it covers the cavity. Use the selected material instructions.
Equipment / stock: imperial. Cuts / workshop layout: cm. Verify before cutting.
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PAGE 14
GARAGE DOOR  /  ASSEMBLY MANUAL
14 / 27
07
Fit the white decorative trim
Dry-fit the pieces on the outside faces of both leaves. Use the same horizontal reference line across the pair.
T1 × 2 per door
T2 × 3 per door
Cut 7.5 cm wide; stock 0.236 in
T1
T2
1
Place the two full-height T1 verticals at the outside edges of each leaf. Fit the three
112.565 cm T2 rails between them.
2
Reference rail lower edges are 0, 103.1825 and 206.365 cm above the leaf bottom. The
middle trim center is 106.9325 cm. Keep the two doors visually aligned.
3
Use the proposed decorative fixing layout on page 23: 10 screws per T1, 6 per T2, into
timber. The meeting-seam section is on page 22. Ease exposed edges and protect cut ends.
ALIGNMENT CHECK
The trim is cut 7.5 cm wide; the hidden 2×4 frame has a 3½ in face. Their middle centerlines agree; their
lower-edge measurements differ. Do not use the trim marks to cut frame notches.
Equipment / stock: imperial. Cuts / workshop layout: cm. Verify before cutting.
14


PAGE 15
GARAGE DOOR  /  ASSEMBLY MANUAL
15 / 27
08
Seal and finish all exposed wood
Protect the door before installation, and reseal any later cuts or drilled preparations.
OUTSIDE
INSIDE
TOP + BOTTOM
HINGE + MEETING EDGES
1
Sand and remove dust. Ease sharp exposed edges enough for coating coverage, without
changing joint bearing or the intended fit.
2
Follow the selected exterior finish system. Cover both faces, all four edges, trim ends and
cut plywood edges. Preserve any intentionally bare bonding areas until their adhesive
operation is complete. [4]
3
Let the coating cure as directed. After fitting hardware or trimming the center cover, reseal
the new holes/cuts and touch up disturbed areas.
FINISH CHECK
Check the top and bottom edges with the leaf still on supports. Those edges are easy to miss after hanging.
Coating counts and cure times come from the selected product, not this drawing.
Equipment / stock: imperial. Cuts / workshop layout: cm. Verify before cutting.
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PAGE 16
GARAGE DOOR  /  ASSEMBLY MANUAL
16 / 27
09
Weigh, check hinges, then hang
Complete the hardware suitability check before a trial hang. Use a helper and secure lifting/support equipment.
LEFT
closes first
RIGHT
opens first
257 cm opening reference
TOP / SIDES  0.635 cm
CENTER  0.6 cm   |   BOTTOM  1.5 cm
1
Record each leaf's actual weight with all fitted parts; include the measured weight of
anything still to be added. Confirm the hinge system, joint connections, fasteners and jamb
for the actual width, weight and exposure.
2
Set the left leaf on secure temporary supports, then the right. Use the measured gaps and
actual hinge template. Keep hinge axes aligned and the leaves level with one another.
3
Fasten to the selected specification while keeping the leaf supported. Test the full outward
swing over the highest floor point before removing temporary supports.
FIT CHECK
The drawn gaps are starting allowances. Actual hinge geometry, trim depth, floor slope and weatherseal
compression control the fit. Do not use the model's ideal hinge pivot as a drilling template.
Hinge quantities on the parts page are planning counts, not load ratings.
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PAGE 17
GARAGE DOOR  /  ASSEMBLY MANUAL
17 / 27
10
Fit the center cover and seal
The right leaf is active. The cover, spacer and gasket move with it.
C1 cover × 1
C2 spacer × 1
S1 gasket × 1
RIGHT ONLY
1
Hold the left leaf closed and secure it. With both leaves aligned, confirm the center gap and
dry-fit the cover across it: 3 cm support on the right + 0.6 cm gap + 2.4 cm overlap
on the left.
2
Select the real gasket, then set C2 to its required compressed working gap. The drawing's
0.118 in spacer and compressed gasket are examples, not the seal's uncompressed
purchase thickness.
3
Cut cover, spacer and seal ends to the fitted head/bottom details. Fix C1/C2 into the right
meeting timber only. Fit S1 under the left overlap so it compresses against the left leaf.
CENTER-JOINT CHECK
The cover releases when the right leaf opens. No screw or rigid glue joint crosses into the left leaf. Check
even compression and easy latch action along the full height.
Equipment / stock: imperial. Cuts / workshop layout: cm. Verify before cutting.
17
CENTER CONNECTION: THE COVER BELONGS TO THE RIGHT DOORT op section through the closed doors. Spacer and gasket thicknesses are working-gap examples.
LEFT • INACTIVE RIGHT • ACTIVE
INSIDE / GARAGE
6 cm cover cut width
2.4 cm overlap3 cm support
S1 • GASKET (MODEL)Width: approx. 0.866 inCompressed: approx. 0.118 inInset: 0.1 cm at each end of overlap C2 • SPACERCut width: 3 cmApprox. 0.118 in thick
C1 • COVERCut width: 6 cmApprox. 0.236 in thick
0.6 cm gap between leaves
OUTSIDE
C1, C2 and the gasket move with the RIGHT leaf.
Stock: imperial • Cuts / marks: cm • V4 model reference • Not full sizeRight opens ﬁrst. Left closes ﬁrst.

PAGE 18
GARAGE DOOR  /  ASSEMBLY MANUAL
18 / 27
11
Fit the latch, bolts and seals
Use the selected hardware and weatherseal templates. Fit each seal to the actual installed gap.
FIT TO SOUND BACKING
LEFT
Two bolts: top and bottom.
RIGHT
Active latch and center cover.
BOTH
Pulls and hold-open devices.
PERIMETER
Head + two sides + two bottoms.
Schematic positions only; use the manufacturer's mounting templates.
1
Install the two left-leaf bolts and their keepers into suitable door framing and supports. Fit
the right-leaf latch, pulls and both hold-open devices.
2
Fit the head and jamb seals to sound stops. Fit the two bottom seals to the actual
threshold/floor condition without using them to support door weight.
3
Join the center seal to the head/bottom weather details. Check for continuous contact, free
movement, water-shedding edges and no trapped lower-edge water.
SEAL LENGTHS
Reference runs: head 257 cm; sides 2 × 216 cm; bottoms 2 × 127.565 cm. These are measuring allowances.
Different locations may need different profiles; final cut lengths follow the installed detail.
Equipment / stock: imperial. Cuts / workshop layout: cm. Verify before cutting.
18


PAGE 19
GARAGE DOOR  /  ASSEMBLY MANUAL
19 / 27
12
Test the opening sequence
Operate slowly first. Support and adjust any leaf that rubs, drops or loads the latch.
1  OPEN RIGHT FIRST
2  RELEASE / OPEN LEFT
OPEN: unlatch and open the right leaf; release the left bolts; open the left. Secure both with
their hold-open devices.
CLOSE: close the left leaf and secure its bolts first. Close and latch the right leaf over the center
gasket last.
Both leaves swing fully without rubbing the floor, jamb, post or one another.
All hinges and anchors remain firm; the latch closes without lifting the door.
The cover releases freely, the gasket contacts evenly, and the seals do not bind.
Finish is complete on edges, ends and later hardware cuts.
AFTER ASSEMBLY
Recheck after initial use and seasonal weather changes. Investigate sag, loose fasteners, damaged finish or
deteriorated seals before they worsen.
Opening poses use the CAD's illustrative axes; verify the actual installation.
19


PAGE 20
GARAGE DOOR  /  ASSEMBLY MANUAL
20 / 27
Complete the assembly record
Use this page with the actual hardware instructions. The manual does not invent a structural screw schedule.
Record
LEFT leaf
RIGHT leaf
Finished width / height, cm
________________
________________
Actual final weight, lb
________________
________________
Hinge model / number
________________
________________
Fastener specification / embedment, in
________________
________________
Jamb material / sound anchorage
________________
________________
FASTENER REACH: CHECK THE MATERIAL STACK
The values below are the layers crossed before the screw reaches timber. Add the selected fastener's required
timber embedment, then check that its tip and head suit the actual assembly. These are geometry checks, not
selected screw lengths.
Fixing location
Layers before timber, inches
Outside skin
15/32 = 0.46875
Inside lining
1/5 = 0.200
White trim through outside skin
0.23622 + 0.46875 ≈ 0.70497
Center cover, example spacer, trim and skin
0.23622 + 0.11811 + 0.23622 + 0.46875 ≈ 1.05930
Hinge or other hardware
Actual hardware + actual intervening layers
Frame joints / reinforcement confirmed; access-dependent fixings completed.
Actual hinge, latch, bolt and hold-open instructions kept with the project.
Both opening directions and all seal transitions checked; later cuts resealed.
Record selected product details; a count or screw length alone does not establish capacity.
20


PAGE 21
GARAGE DOOR  /  WORKSHOP DETAILS / 1 OF 6
21 / 27
Which strip do you cut?
Six different pieces have different jobs. Quantities below cover both doors.
ID
Qty
Cut L × W, cm
Stock thickness,
in
Job / cuts
P2
2
213.865 × 5.325
15/32
Outside infill. Rip width; square ends.
P4
2
213.865 × 5.325
1/5
Inside infill. Rip width; square ends.
T1
4
213.865 × 7.5
0.236 model
Vertical trim. Cut length; rip if wider.
T2
6
112.565 × 7.5
0.236 model
Horizontal trim. Square ends between T1.
C1
1
213.865 × 6
0.236 model
RIGHT center cover. Fit final end cuts.
C2
1
213.865 × 3
0.118 example*
RIGHT spacer. Fit thickness and ends.
CUTTING SEQUENCE
1
Measure before ripping. Infill width = actual leaf width − usable main-sheet width − joint gap. The model
gives 127.565 − 121.92 − 0.32 = 5.325 cm. Existing strips can be reused if their size, flatness and exterior
suitability match.
2
Support the sheet and the offcut. Clamp a straight guide to a stable work surface. Put the blade kerf on
the waste side of the finished-width mark. Keep the narrow strip supported; use the saw’s guarding and
narrow-cut method.
3
Make square end cuts. T2 uses simple 90° butt ends between T1; no 45° miters or half-laps. Dry-fit before
the final end trim. Cut one test piece, then repeat with a stop or matched marks.
4
Label each piece. Mark its ID, leaf and face on the back. Sand the cut edge and protect it with the chosen
finish system, preserving any areas required bare for a later bond. [4]
STOCK AND FIT
*C2 follows the gasket’s compressed working gap; 0.118 in is an example. Trim model: 0.236 in, not exactly
¼ in. Verify actual stock and door dimensions before cutting.
Equipment and stock: imperial. Cut lengths, cut widths and workshop marks: cm.
21


PAGE 22
GARAGE DOOR  /  WORKSHOP DETAILS / 2 OF 6
22 / 27
Fix the plywood strip first
P2 fills the skin width. T1 is a separate decorative cover over the supported seam.
1
Hold the 0.32 cm seam with removable spacers. Place P2 at the meeting edge, with the full strip and
both seam edges supported by the 3½ in wide stile. Fasten P2 independently before fitting T1.
2
P2 fixing: use exterior wood screws with heads that retain the plywood, seated flush for the trim. A
measured 1¼ in screw gives about 0.781 in geometric reach into timber. Panel-to-frame spacing/count and
bonding must suit the actual structural skin.
3
P4 inside: the 1/5 in lining also fixes into the stile. A measured 1 in screw reaches about 0.800 in into
timber. A low-profile pan/washer head helps retain a thin liner; test the actual head and do not crush the
veneer.
COVER THE SEAM; KEEP ITS MOVEMENT SPACE
Remove the spacers once the strip is held. Leave the panel joint open beneath the trim. Keep any trim
adhesive on the infill side; do not make a rigid bridge between the two plywood sheets. [2]
P2/P4 screw lengths illustrate reach only. Confirm the structural skin connection separately.
22
GARAGE DOORS / ASSEMBLY DETAIL
How the narrow strips are ﬁxedLEFT meeting stile - top view - cuts / layout: cm; stock / hardware: imperial
T1 decorative trimP1 + P2 outside plywoodF1 timber
1
2T1
P1 P2
F1 meeting stileSound timber behind both pieces
P1 continuesacross the leaf
T1 cut width 7.5 cm
OUTSIDE
0.236 in*
15/32 in
1-1/2 in
P1 bearing 1.278 inP2 cut width 5.325 cm
Set gap 0.32 cm2×4 stock: actual timber face 3-1/2 in
Meeting edge of LEFT door
1 T1 ﬁnish screwGRK #8 × 1-1/2 in; T10.Drawing length: 1.55 in.Geometric reach: 0.845 in.Axis: 3.75 cm from leaf edge.Pilot/countersink: test inyour actual thin trim ﬁrst.
2 P2 screw before trimBroad bearing head; setﬂush.Do not crush the plywood.Axis: 2.663 cm from leaf edge.Select length for actual ﬁxing.Oﬀset from the T1 screwsalong the strip's height.
Keep the seam freeDo not rigidly glue T1 toboth plywood pieces.The 0.32 cm gap remainsbehind the decorative trim.P2 screw length is schematic.
Screw paths are oﬀset along height; this schematic section shows both paths together.*Trim is 0.236 in in this model; verify actual stock (not exactly 1/4 in). Screw proﬁle is illustrative; follow the screw maker.

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Screw on the decorative trim
Proposed retention for flat exterior plywood trim; modeled stock thickness 0.236 in.
Example: GRK FIN/Trim, pack label #8 × 1½ in, T10 drive, appropriate exterior coating or stainless variant for the
wood and exposure. Drawing length: 1.55 in; geometric reach through 0.23622 in trim + 15/32 in plywood: 0.845
in. Measure the purchased screw. [6, 7]
1
Dry-fit and clamp. Mark the hidden stile/rail lines on the skin. Put one screw row on the strip centerline,
3.75 cm from its long edge. Offset holes along the height to miss existing skin fasteners.
2
Test the drilling on matching offcuts. A clearance hole is in the strip; a smaller pilot is in the timber.
Choose them for the actual screw and wood. The small trim head is only about 0.197 in wide: keep adequate
head bearing; do not make a large generic countersink.
3
Drive gently to flush. Use a low drill clutch; finish slowly. The head must retain the 0.236 in strip without
crushing or pulling through it. Fill individual cosmetic recesses with exterior filler, sand and finish. No
full-width glue bed is required for this proposal.
Counts for both doors: 4 T1 × 10 + 6 T2 × 6 = 76 trim screws; center-cover screws are additional. This proposed pattern
holds decorative trim; it is not the frame, skin or hinge fastening schedule.
First / last screws: 5 cm from ends. Intermediate spacing: T1 ≈22.65 cm; T2 ≈20.51 cm.
23
GARAGE DOORS / ASSEMBLY DETAIL
Where to screw the decorative trimCuts / layout: cm - stock: 0.236 in exterior plywood trim in this model; verify actual stock
Cut envelope 127.565 cm
Cut envelope 213.865 cm
Continuous plywood facebeneath the trim
LEFT leaf shownMirror for the RIGHT leaf
T1
T2
ScrewTrim Timber behind
T1 / 2 vertical strips per leafCut 213.865 × 7.5 cm; stock 0.236 in thick10 screws per strip
5 cm end margin + 9 equal gaps of 22.652 cm + 5 cmScrew row: 3.75 cm from either long edge.
T2 / 3 horizontal strips per leafCut 112.565 × 7.5 cm; stock 0.236 in thick6 screws per strip
5 cm end margin + 5 equal gaps of 20.513 cm + 5 cmScrew row: 3.75 cm from either long edge.
38 screws per leaf2 × 10 + 3 × 6 = 38 | 76 for both leaves
DECORATIVE TRIM ONLYThis is not the frame, hinge or plywood ﬁxing schedule.Every trim ﬁxing must enter sound timber underneath.Center cover C1 and any extra hardware are excluded.
Proposed screw layout for lightweight, ﬂat trim. Conﬁrm the actual materials and ﬁxing product before cutting or drilling.All orange dots land over modeled timber. Cut/layout values are not workshop tolerances. Model 0.236 in trim is not exactly 1/4 in.

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Fasten the center cover
The center cover and spacer attach to the RIGHT leaf and release with it.
C1: 6 cm total width
TOP VIEW • OUTSIDE IS ABOVE
LEFT timber
RIGHT timber
free overlap + gasket
screw enters the stile
1.5 cm
C1: 0.236 in thick
C2: 0.118 in example
T1: 0.236 in thick
P2: 15/32 in thick
Cover width: 2.4 cm free LEFT overlap + 0.6 cm center gap + 3 cm RIGHT support. Modeled gasket profile:
approximately 0.866 in wide within the overlap. Its compressed gap sets the actual spacer thickness.
1
Close and secure LEFT; align RIGHT. Fit the gasket first and select C2 thickness. Cut the cover and spacer
ends to the actual head and bottom seals. Their 213.865 cm reference length may need end trimming.
2
Mark the fixing row on RIGHT only: 1.5 cm inside its meeting edge, centered over the 3 cm spacer. On
the cover this is 4.5 cm from its left edge. Stagger holes to miss P2/T1 screws.
3
Example cover fastener: exterior-compatible GRK FIN/Trim #8 × 2 in, drawing length 2.00 in. Through
the example 1.05930 in stack, geometric timber reach is 0.941 in. Test the head and drilling as on page 23.
[6, 7]
4
Example cover count: 10 screws, about 5 cm from fitted ends and evenly spaced at no more than about 25
cm. Keep the cover removable. Open RIGHT first and verify that its free overlap clears LEFT.
KEEP THE TWO LEAVES INDEPENDENT
These are weather-cover fixings. Fit handles, latches and other loaded hardware to suitable framing. No
cover screw goes into the center air gap or crosses into LEFT.
Section is a fixing schematic. No screw count here rates the door or its hardware.
24


PAGE 25
GARAGE DOOR  /  WORKSHOP DETAILS / 5 OF 6
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Mark every frame notch
Keep sound existing joints. This cut map is for replacement F1 uprights and F2 rails.
Member / face to remove
Notch ranges, cm, from one squared reference end
F1 upright / OUTSIDE half
0–8.89; 102.4875–111.3775; 204.975–213.865
F2 rail / INSIDE half
0–8.89; 118.675–127.565
1
Crosscut blanks square: F1 = 213.865 cm, four total; F2 = 127.565 cm, six total. Keep the 2×4 laid flat:
3½ in face × 1½ in depth. No lengthwise ripping of the frame stock is planned.
2
Label faces and one reference end. Use the actual mating board to mark each notch width. Set the cut
depth to half the actual thickness: 1.905 cm for actual 1½ in thick stock. The two members lose opposite
halves.
Do not cut F2 to 109.785 cm. That is the clear span between uprights. The full-width rail includes its two end overlaps. Model
decimals are layout references, not a promise of site precision.
Both completed faces should be flush; combined joint thickness equals the original timber depth.
25
WORKSHOP DETAIL 01 • BOTH DOORS • CUTS / MARKS: cm • STOCK: IMPERIALExactly where to cut the frameHalf-lap joints: remove half the thickness from opposite faces, then overlap.Keep sound existing joints. Replacement stock: nominal 2×4, actual 1-1/2 × 3-1/2 in.F1 UPRIGHT ×4 CUT LENGTH 213.865 cmOUTSIDE broad face facing you • bottom at left; top at right
HATCHED = WASTEREMOVE HALF DEPTH
0.0008.890 102.488111.378 204.975213.865Notch depth = half the actual board thickness. For 1-1/2 in timber: cut 1.905 cm deep.
F2 CROSS RAIL ×6 CUT LENGTH 127.565 cmINSIDE broad face facing you • a half-lap at each end
FULL-WIDTH RAIL — THE ENDS OVERLAP THE UPRIGHTS
0.0008.890 118.675127.565
SECTION THROUGH THE LAPTogether, the two retained halves fill 1-1/2 in.
F2 retains OUTSIDE halfF1 retains INSIDE halfEach retained half = 3/4 in for this model.
EXACT LAYOUT MARKSF1: 0–8.890 | 102.4875–111.3775 | 204.975–213.865F2: 0–8.890 | 118.675–127.565Measure from one squared end; mark with the actual mating board.The F2 rail is 127.565 cm long, including both overlaps.Do not use the clear opening between the uprights as cut length.
Cut maps are model dimensions, not site measurements. Verify timber, leaf size and squareness before cutting.Cuts / layout marks: cm • Purchased stock: imperial • Rounded labels are not a cutting tolerance

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Cut and fit the half-lap
Start with two offcuts of the actual timber. A handsaw and sharp chisel are enough for the trial.
1
Knife the shoulder lines and mark the depth on both edges. Secure the board to a firm bench and
support its length. Put the saw on the waste side of the line; a small chiseled starter helps locate the cut. [8]
2
Saw shoulders, then relief cuts. A center notch has two shoulders; an end lap has one. Stop short of the
final depth line so the last thin amount can be pared accurately.
3
Remove small chips with the chisel. Work from each edge toward the middle, keeping hands behind the
cutting edge. Pare the floor flat to the line. Do not lever against the retained half.
4
Dry-fit the complementary pieces. Faces should be flush, shoulders touching and the joint free of rocking.
Pare tight high spots; remake a loose or overcut piece. Clamp the full frame flat and compare both diagonals:
reference 249.020 cm.
AFTER THE DRY FIT
Cutting accuracy does not select the structural joint connection. Complete the confirmed bonding, fasteners
and racking reinforcement for the actual timber and leaf load before adding skins or hanging.
Cut depth: 1.905 cm in each mating piece. Timber stock: 1½ in thick. Verify actual stock.
26
WORKSHOP DETAIL 02 • HANDSAW + SHARP CHISELCut one test joint before cutting all piecesUse two offcuts from your actual timber. Check face labels every time you turn a board.Clamp the board to a solid bench. Support the long length. Keep hands clear of the cutting path.
1 MARK THE SHOULDERS + HALF DEPTHactual mating width
depth line = half actual thicknessSquare the blank to length; label OUTSIDE and INSIDE.Use the mating board to mark the lap width. Knife theshoulders and mark half depth on both narrow edges.
2 SAW THE SHOULDERS, THEN RELIEF CUTShandsaw cuts in the waste
STOP short of the depth line; pare the last small amount.
Make a shallow starter on the waste side of the line.Middle notch: two shoulders. End lap: one shoulder.Add relief cuts; keep them above the depth line.
3 REMOVE WASTE; PARE THE FLOOR FLAT
chisel
Blue floor = the retained half. Finish exactly to the line.
Remove small chips between the relief cuts.Work from each edge toward the middle; take thin cuts.Keep both hands behind the sharp edge. Pare flat.
4 DRY-FIT THE OPPOSITE HALVES
RAIL: retained OUTSIDE half
UPRIGHT: retained INSIDE half1-1/2in*
Broad faces flush; shoulders touching; no rocking.If tight, pare high spots; do not hammer the joint.If loose or overcut, remake it; do not fill for fit.Dry-fit the frame flat and check equal diagonals.
*For the nominal model. Match the real board thickness. Cutting diagrams do not specify structural joint fastening.Method reference: Lee Valley Tools, “Mastering Handsaw Cuts” (Christopher Schwarz). Illustrations are original.Cuts / marks: cm • Stock / equipment: imperial • Process diagrams are enlarged, not full-size templates

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Design notes and references
The drawings show the current V4 geometry and your stated material thicknesses. Product instructions control
product-specific assembly.
DESIGN BASIS AND USE
Reference opening: 257 × 216 cm; leaf cuts: 127.565 × 213.865 cm. Stock: 15/32 in outside plywood, 1½ in
core, 1/5 in lining; trim model 0.236 in. Use imperial for purchases and cm for cuts/marks. Quantities cover both
leaves. Verify actual stock and site dimensions.
Keep sound existing framing. Pages 21–26 add workshop methods and a proposed decorative-trim fixing layout.
They do not establish structural, wind, fire or thermal performance. Verify actual frame connections, panel bracing,
hardware and foam covering for the installation.
[1] APA — Plywood exposure classifications — Verify the exterior-use marking; thickness alone does not define exposure
suitability.
Open primary reference
[2] APA — Prevent Buckling with Proper Spacing — General panel spacing guidance; the supported 0.32 cm seam is this
project’s detail.
Open primary reference
[3] Henkel — LOCTITE PL 300 technical data — Check exact foam, facing, substrate, retention and cure; no sandwich-panel
rating is implied.
Open primary reference
[4] Simpson Door Company — Care and finishing — Protect faces, edges and later cuts using the selected coating system.
Open primary reference
[5] Titebond III — Manufacturer limitations — Exterior-use glue is not a structural door-joint specification; stated limitations
apply.
Open primary reference
[6] GRK — Finish Trim Head product — Exterior-trim application, finishes, T10 drive and pack labels. Our spacing/counts are a
proposal.
Open primary reference
[7] GRK — Finish screw drawing, dated 11/01/2023 — Nominal #8 × 1½ in product: drawing L = 1.55 in; #8 × 2 in product:
L = 2.00 in. Measure purchased parts.
Open primary reference
[8] Lee Valley Tools — Mastering Handsaw Cuts — Christopher Schwarz: knife-marked shoulders, waste-side saw starts and
securely clamped work.
Open primary reference
Unit convention updated 09 October 2026. CAD geometry and workshop illustrations are original. Retain the exact cm cut list and
3D model with this manual. Screw reach is geometric penetration, including the tip; it is not a load-capacity calculation.
Assembly edition / V4. Revise the model, cut list and manual together if dimensions change.
27
