Author Topic: Replacing a rotten section of my cedar garage door  (Read 3278 times)

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Offline Frank Pellow

  • Posts: 2748
  • Toronto, Ontario and Lake Pivabiska, Ontario
Replacing a rotten section of my cedar garage door
« on: June 11, 2011, 07:21 PM »
I painted all four of our exterior doors this week and, while preparing to do so, encountered a big patch or rot in our cedar garage door:

39122-0  39124-1    
    
I cut a large rectangle out of the door using a cut-off jig saw blade in order to avoid the metal frame that backs parts of the door:

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And, in a couple of places, I used a chisel:

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The rest of the door was then lightly sanded:

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From my considerable supply of rough sawn and mostly knot-free cedar, I fashioned the insert shown below:

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The top of the insert has a grove to hold the panels above.  The bottom and sides of the insert and well as the top and sides of the cut-out were coated with several coats of green preservative.

The insert had to be cut into three segments in order to fit it into the door:

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The inserts were attached to the door and to each other with several screws:

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Auto body filler was applied liberally over the joints and over the screw holes:

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Then the area was sanded using these two sanders:

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The patch could now be painted:

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Finally, a second coat was painted on the entire door:

39144-11
    
It’s difficult to spot the patch.  [smile]

« Last Edit: June 11, 2011, 07:28 PM by Frank Pellow »
Cheers,   
               Frank (Festool connoisseur)

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