garage door repair

12 years ago

Hello. am new to this forum and was wondering if I could get some advice on my garage door. have an older door with what looks like a masonite covering over a wood frame. the bottom 2 inches or so has deteriorated from exposure to water. tried peeling back the outer covering and noticed that the interior of each panel has what I would call a honeycomb pattern made out of cardboard. the outer covering is glued to this and is very strong. would like to keep this door as the torsion spring was replaced about a year ago and the frame is in excellent shape.
Question is how would I go about replacing the outer panel keeping in mind how it is constructed. any help would be appreciated

Featured Answer

millworkman

9 days ago

Mark Manson - 12 year old post.....................

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Comments (7)

PRO
Joseph Corlett, LLC
12 years ago
Buy a new lower section and install it.
cappo11
Original Author
12 years ago
I didn't mention I would like to redo the entire outer surface of the door as the other panels are rather weather beaten also. Don't want to buy new panels but rather repair.
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geoffrey_b
12 years ago
You are going to have to replace the bottom lower section. and the door gasket.

Compare that to a price of a new door.

If you buy a new lower section. Seal it well with paint - all six sides - before you install it.

All you can do is sand the rest of the door, prime, and paint.

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cappo11
Original Author
12 years ago
Thanks Geoffrey_B. Possibly a new door might be more cost effective
millworkman
last year
Christopher 11 year old post and what if the OP is not in Coral Springs?
PRO
Mark Manson
9 days ago
Welcome to the forum!What you have is a classic torsion-box hollow-core door using a paper/cardboard honeycomb core. That setup is incredibly strong structural-wise, but as you noticed, Masonite acts like a sponge once water gets past the paint and bottom seal.Since your spring and frame are in good shape, here is how you can repair that bottom section without rebuilding the entire door:
1. Scrape & Cut Back: Cut away the rotted/swollen Masonite until you reach clean, dry wood and undamaged honeycomb.
2. Clear the Water Damage: Scrape out any soft, ruined cardboard in that bottom 2–3 inch section.
3. Solid Block Reinforcement: Instead of trying to recreate the honeycomb at the very bottom, fit and glue a solid wood strip (like clear pine or exterior-grade plywood) into that bottom gap to act as a solid base block.
4. Patch the Face: Use an exterior-grade wood filler (or Bondo/epoxy fairing compound) to bridge the seam between the old Masonite and your patch, then sand smooth. Alternatively, glue a thin exterior plywood or smooth hardboard skin over the entire bottom panel section using exterior construction adhesive.
5. Seal thoroughly: Coat the bottom edge generously with exterior oil-based primer and paint. Be sure to add a new rubber bottom weather seal to keep water from wicking up in the future.
Good luck with the repair!