Expert: Stephen Major (Owner--Major Design Group) - 6/28/2007

Question
QUESTION: Is it possible to take a steel garage door and put plywood on it to make carriage house doors.  If this is possible, where would I find the directions on how to do this?
Thanks for your time.
Kathryn

ANSWER: Kathryn,

You don't say whether the steel door is a segmented overhead door, a 1-piece overhead door, or a swinging door.  

Attaching plywood to a steel door is usually not a good idea,  It is heavy and will usually overtax the hardware (hinges, tracks, etc). If you want the appearance of carriage house doors, consider attaching primed and back-primed cedar 1x4s and 1x6s to the door, using construction adhesive and trim-head screws.  Use the wood rough-side out.  When finished, prime the whole door and trim, caulk any visible gaps, and paint with a high quality acrylic latex house paint.

If you require additional information, or if you want to elaborate on your original question, please let me know.

--Steve Major

---------- FOLLOW-UP ----------

QUESTION: I have not purchased the door yet, so it could be steel or aluminum.  I was looking to buy a segmented door that would be on a track.  Do you know of any place on the Internet or a book that might have directions to do this.  Thanks so much for taking your time to answer my question.  I really appreciate the help
Sincerely,
Kathryn Crow

Answer
Kathryn,

I would need to do the same as you - search Yahoo, Google, etc. on a variety of key words/phrases.  

I doubt that you will turn up much in the way of actual plans.   This is really a detail-oriented carpentry project.  You need to choose the pattern of framework that will be on the door, then purchase wood and other materials as needed.  Then you will need to carefully cut the pieces to match the look you want, taking into account the fact that the door is segmented and must move and continue to resist the weather.

We (Major Design Group) have the in-house capability to produce a custom design and instructions for this, but our professional hourly rate will probably scare you away from this option.  

Let me know.  Otherwise, best of luck and happy web searching!

--Steve Major