Introduction: Homemade "Carriage House" Garage Doors

Picture of Homemade "Carriage House" Garage Doors

This is a step-by-step on how your average schmoe can build beautiful "Carriage House" style garage doors.

I'm a computer programmer and this is the first time I've done anything like this.  I made it happen, so I think anybody armed with minimal carpentry skills and these simple instructions could get as good of results!

Finally, if you're looking for similar wood ideas, check out this site.  I'm not affiliated with, nor have I even done business these guys (yet).  I just find the projects are quite inspiring!


UPDATE: Looks like I didn't win anything. :_(
Oh well, many thanks to everyone who voted!

Also I should add that these doors have survived the winter well, including several heavy wind storms.  It appears that the design is sound and should last for quite some time.  (Unlike my shed roof which, well... lets just say there's never a dull moment around here.)

Step 1: The Boring Backstory

Picture of The Boring Backstory

Okay, so I recently bought a house and noticed there were slight gaps between the garage doors and the wall.  "Slight", as in, so big you could shake hands with somebody outside -- with the door closed! 

Having heard the horror stories of the limb-rending power of garage door springs I opted to shelve my DIY nature and hire a guy to come out for this one.  The dude looks it over and says, "I could probably fix that if you really want me to, but these kind of doors are such junk that the manufacturer has gone out of business".  Spiffy. 

I had him rip them out, but that left me with gaping holes in my house in the middle of winter.  Uh oh.  Now what?

Step 2: The Solution

Picture of The Solution

So, let's get problem solving.  Here are the engineering 'forces' at work:
* The doors should be inexpensive, therefore, most likely...
* They have to be something I can build my self.
* I'm a DIY guy, so no more of this "hiring people to come out" business.  Ergo, no deadly springs.
* Since I enjoy sleeping indoors they should look great for my wife.
* The garage ceiling is really short, so overhead doors were really not smart to begin with.
* Have to be well-insulated for the climate I live in.

After looking around, I discovered that many of the more expensive overhead garage doors are designed to look (rather unconvincingly, IMO) like old-fashioned, side-opening, "carriage house" doors.  Well, isn't that interesting?   Expensive-looking, side-opening doors... made of wood and traditional carpentry techniques...  I can handle that! :)

After scavenging online however, I found very little information on actually how to do this.  There were lots of questions in woodworking and farm diy forums on the subject, but very little in the way of answers. 

The best I found was This Tutorial but even that wasn't exactly what I wanted.  It uses more difficult "mortise-and-tenon joinery", is uninsulated, and kindof an art deco / cubist style.  (Still, a maybe good reference if you're wanting doors more along those lines.)

All that to say, hopefully THIS tutorial can be helpful to others wanting to build a similar design.

Step 3: The Plan

Picture of The Plan

Admittedly when I first started out I didn't have much to go off.  I just went to the lumber store and wandered around aimlessly until something clicked. 

Naturally, they didn't have a "carriage house garage door building kit", but what if... what if I'm not trying to build a "garage door" at all?  No, listen.  What if what I'm really trying to build is just a simple wooden gate (that just happens to fit inside a hole)?   Off to the fence section...  let's see...  outdoor-grade cedar planks...  steel gate support brackets...  hinges...  decorative handles...  the mother lode, baby!

So what we're going to do is create a basic framework out of 2x4 lumber and steel brackets and fasten it to the door frame with black hinges.  Then we'll put in some nice windows (they had some on clearance) and some "board and batten" siding made from cedar fence pickets.  Finish it all off with some rigid foam insulation on the inside and maybe some gate handles for gravy.

All-in-all, they should look stellar for about, lets see... $200 per section... times two sections per opening... and two openings...

I'm getting both doors for about $800 in materials -- or probably about half the price of one "normal" garage door. 

If only I knew what I was doing this plan would be perfect! ;)

Step 4: Doorposts (intro)

Picture of Doorposts (intro)

My first problem was that I could probably build doors just fine, but there is brick on both sides of my garage door opening. 

If you have wood or metal-covered wood around your garage door opening, then you could optionally skip ahead to actually building the door.  Even so, the posts were only like five bucks apiece so you could use them to help plumb in a not-so-vertical opening, or for just plain looks.  Up to you.

For this tutorial-within-a-tutorial, what you need is some 4x4 cedar posts, some masonry anchors and to beg, borrow, or rent a hammer drill with masonry bit of appropriate size.

Step 5: Doorposts (anchoring to Masonry)

Picture of Doorposts (anchoring to Masonry)

After doing some research online, there is great debate on how to do this properly.

The first debate is whether or not you need 1/2 inch expanding masonry anchors (full-length for brick, or shorter ones for concrete).  The alternative is to use a bunch of "Tapcon" masonry grabber screws.  Tapcons don't need as big of holes but they are generally intended more for things like attaching electrical boxes which is why I opted for the more heavy-duty solution.

The other big debate is whether to drill into the bricks themselves, or into the horizontal mortar joints (the vertical mortar joints will assuredly pull out) between them.  If you anchor into the brick you get less likelihood of crumbling and more holding power.  On the other hand, anchoring to mortar joints is still quite strong and gives you the ability to easily remove the anchors and patch the holes in the future.

I went with bricks, cuz I'm just a bold fellow like that. ;)

Line up, plumb, and mark where the posts will go.

Drill the holes in the posts FIRST, then use that as a guide for drilling the brick.  If you are an ijit and do it the other way around (like me) then the anchors tend to be all over the place and not very perpendicular to the wall.  This makes drilling and fitting the posts a very tricky job.

Step 6: Figuring Out the Door Frames

Picture of Figuring Out the Door Frames

What you want to do is measure the total opening, top, bottom, left, right, and (vertical) center.

While you're standing there with a measuring tape, divide the top and bottom measurements in half and mark the floor and ceiling centers for reference.

For your frame, the horizontal (halved top and bottom) measurements should be subtracted by 1/2 inch:
That is, 1/4 inch for the hinge side and another 1/4 for the center. (Yes, that's 1/2 inch total in the center when you consider the 1/4 inch off from each door's center side.)

The vertical (left, right, and two centers) measurements should be subtracted by 8 inches:
That is, two 3 1/2 inch (top and bottom) studs plus two 1/8 inch brackets between, plus 1/4 inch on the top and 1/2 inch on the bottom.
If your outdoor concrete is very un-level then you may want a bigger bottom gap.  (I probably should have.)

Step 7: Building the Door Frames

Picture of Building the Door Frames

I bought a gate kit instead of individual support brackets for the door frames.  It's about the same price either way, but I just liked that the support brackets were welded to the hinges.   No big deal, I'm sure. 

NOTE:  If you buy the gate kit pictured earlier, do not, I repeat DO NOT use the screws that comes with it!  Seriously, they are nasty and cost me several hours time!  Just put away the Scrooge MacDuck and get yourself a bucket of decent grabber screws.  You'll be glad you did.

Cut vertical and horizontal studs to the lengths calculated in the last step.  Don't forget to mark which piece is which as you cut since they're not necessarily interchangeable. 

Screw the support brackets onto the horizontals first, starting 3 1/2 inches in from the edge to leave room for the verticals.  Next, attach the verticals and only the top and bottom hinge.  (The middle hinge comes later.)

Step 8: Hey! That Looks Almost Like a Door!

Picture of Hey!  That Looks Almost Like a Door!

If all goes well, your door should fit perfectly into the opening!  If, on the other hand, you're a real human being and not a robot, then decide what's the wrong length, take it out, and fix it.  Repeat as necessary.

Okay, now your door should fit perfectly into the opening!

Find a 1/2 inch (or whatever you decided for the bottom gap) piece of scrap and place it under the door near the post.  With the door in the 90 degrees open position, start sliding scrap under the outside bottom of the door until your hinges are aligned.

HINT:  You can either line up your hinges from the front, or, I found it easier to measure about 2 inches from the back of the post and line up to that.

Once you're happy that everything is square and nicey-nice, screw the hinges in.  If you have an A/B personality thing going on, you could trace around the hinges and chisel out a recess for them.  I didn't bother.  Maybe someday.

This should leave you with two stud door frames that open and close smoothly.  Again, don't be too surprised if they're not perfect on the first try.  Also, irregularities in the floor and ceiling will likely require a little planing and / or re-doing.  Just be patient and stick with it.

Step 9: Window Sill and Third Hinge

Picture of Window Sill and Third Hinge

From here, things get a little more personal.  You could take this basic frame any number of creative directions. 

I chose to do 24 inch high windows starting beneath the top support brackets.  Using that as a hint I installed a 2x4 for a window sill using cheap, galvanized steel, 'L' brackets (you know, from that section of the hardware store where they have all those metal post setting / hurricane straps / deck building brackets and things).

Working under the assumption that that height was where I wanted more support, I opened the door, pressed my third hinge tightly into the gap (yet flat on both the door and the post), and attached it.

Step 10: Board and Batten Fun

Picture of Board and Batten Fun

After a full day of battling bad screws, math mistakes, and doors that just wouldn't fit right, I needed a bit of relief.  The siding sure provided it!

First off, what to put under the siding?  I had bought some 1/4 inch MDF for this, but reconsidered because I didn't like how it would add lot of weight.  For a good barrier with less weight, a person could do some Tyvek or other brand of "house wrap".   Eventually I decided that since I'm already planning on rigid foam insulation inside the door, and since that stuff is used on the outside of foundations and things, I figure I could just caulk around it and it should be as good a seal against moisture / pests as anything.  We'll see.

HINT:A power miter box saw and a 16 (or maybe 18) gauge nail gun really make this job go fast.


The boards:
Lay out your boards and space them so you can see how much gap in in between.  It should be about 1/2 inch -ish.  On this set of doors it worked out to about 3/8 inch gaps so I didn't even have to rip any planks!

Saw the boards to length.

Starting with the top of each board, use some scrap as a spacer to get your gap consistent and pop in one nail on the outboard side of the plank.  Then move to the bottom with your spacer and drive in two more.  One more in the top completes that board.

Alternate sides between boards so any inconsistencies get pushed towards the center.  The last two or three boards should be spaced by measurement (or by keener eye than mine) to evenly absorb the accumulated differences.

When you're done your door looks like picket fence.


The battens:
You can buy 1 inch wide cedar for this, but wood that small from the store tend to be warped.  I chose some consistent-looking planks and ripped them myself.   This stuff awesome and cuts like butter.

Believe it or not these are even faster easier to install than the boards.  Center the batten over the top gap and pop in a nail right through the middle.  Ditto on the bottom.  Done!


Conclusion:
This "board and batten" siding looks spectacular and was so quick and fun that now I'm looking for other random things to do it to!
At this point I also decided to quickly screw on the handles for coolness' sake.  I may be jumping to conclusions here, but I begin to have the nagging feeling that this idea might actually work! :)

Step 11: Window Mods

Picture of Window Mods

As I mentioned, I found some windows on the cheap. (There's a turbulent tale behind that adventure that I dare not get into here.)  You don't have to wait  for the box store to have a sale, either.  Check craigslist and your local classifieds.  People are always trying to get rid of brand new windows that just wouldn't fit their project.

The problem was is that what I'd found were two sliding glass windows.  What I needed was four fixed glass windows.   The first door was obvious.  Just remove the sliding halves and use them.  For the second door, I had to ("had to", mind you) bust out the gratuitous violence.

First thing, chop the unneeded half off.  This is important to do first as it gives you a peek inside the end to see how the window was made.

Second, you need to cut off the window track.  Things to beware of are:
1) Don't cut through the piece that  holds the weatherstripping.
2) Look metal things inside the frame like screws and steel stiffening bars.
3) If your saw blade brushes the glass you'll suddenly have about 10,000 razor sharp shards in your arms.

I'd show you the jig I rigged up to do this, but suffice it to say I care for neither the accompanying fame nor liability for showing it to people. ;)

Step 12: Installing Windows

Picture of Installing Windows

Installing windows... lets see... open the software box, read the contract that it's too late to not agree to, insert disc 1...
Oh wait.  Wrong windows.  (Wakka, wakka.)

What we really need to do is to install a top window sill and then some brackets to hold the window in.

The top sill is attached with more "L" brackets just like the bottom.  Unlike the bottom, however, I had to notch the end of the board to fit around the top fence brackets.  I came up with a jig to do this on a bandsaw, and unlike the last step, I am willing to share details on that upon request.

Once the top sill was installed I wanted to secure the window in such a way that it wouldn't fall out, but it would also essentially "float" in the opening and any deformation of the door (when opening and closing) wouldn't torque the glass.  I decided on a 3-point system where the bottom two are "U" brackets and the top consists of a plate on each side to get the glass in and out.  (See: the last two pics, below.)

Step 13: Final Siding And... DONE!

Picture of Final Siding And... DONE!

You could probably come up another design that hides the nails better, but here's what I did:
1) Cut and fit uprights from the top of the existing boards to the top of the window opening.
2) Install boards across the top.
3) Add 1" strips inside the window opening, top and bottom.
4) Add top battens and also 1" strips across the full length for window sills.

Step 14: Appendix: Finishing Touches

Picture of Appendix: Finishing Touches

Finishing the Outside:
I bought a gallon clear finish for the wood.  Any fence / deck stain / sealer could work though.  I personally wouldn't use anything opaque on real cedar.  They make fake board and batten siding sheets that are cheaper if you're just going to paint.

I've also got a jug of tar driveway repair stuff  that I'll probably use on the bottom of the posts.


Finishing the Inside:
This is even more a matter of personal taste than the outside look.   I'd stay away from sheetrock due to cracking, but you could paint some hardboard ("masonite") to match your walls, do some tongue and groove paneling, cut a sheet of bead board, or even cover the whole thing with pink shag if that's what goes with your room.


Weatherstripping:
For the top and sides I plan to  run a strip of cedar along the inside.  Naturally there would be a rubber strip between this and the door.  For the inside and bottom I'll use normal garage door rubber.


Opening and Closing:
Right now I'm not actually planning on using the doors for anything, so I'm just screwing them shut.  If you want yours to open, decide how often they'll be used and if you want to get in from the outside.  Some options are:
* Simply "pin" the doors shut from the inside with top and bottom gate pins. (most secure)
* Somehow modify a gate latch to work.
* Rig a standard garage door opener to open them for you.  There are actually several plans on line for doing this.  In fact, that other tutorial I mentioned in the beginning even has a section on doing just that.

Comments

ColinL5 made it! (author)2015-05-18

Thanks for posting such a great and detailed instructable. I recently helped a neighbor build doors based on your ideas here so he can retrofit his garage with a lift for the Triumph cars he collects/restores. The project turned out great!

todjpeter (author)ColinL52015-10-27

Hinges. Where did you get your hinges?

ColinL5 (author)todjpeter2015-10-27

The gate hinges can be found at Lowes.

http://m.lowes.com/pd/Homax-No-Sag-Easygate-Bracket/3262655?

Aram9012 (author)ColinL52015-09-05

Wow! This looks amazing! Would you mind sharing a few details about the layers you used and where you deviated from PS118's guide?

Is it just a board fastened to the internal frame, and then decorative trim added on top of that? So your door is a little thinker than PS118's right?

Id' really like to build this!

ColinL5 (author)Aram90122015-09-05

I wish we had written it all down and done our own instructable, but roughly….we used 2x4s for framing screwed into the steel garden gate hardware in the corners. We added 2x4 boards across the middle in both directions for each door, then attached a 1/8" plywood sheet to the back, filled the cavities with foam insulation board and put another plywood sheet on the front. Attached the whole sandwich together with wood glue and nail gun. Then used wood trim on the front, including a small overlap piece to cover the middle crack. Finally when they were hung, we added trim to the inside of the doorway that had rubber foam attached so when the doors are closed its a good seal against air and light.

Getting everything square is really important. And our garage door openings were all over the place, and the concrete floor wasn't level either which was a real challenge to get the doors to hang straight, swing together, and not pinch.

Note also that yes, our doors are probably a bit thicker hat PS118 and because of that we had to add trim pieces around the entire door opening so there was room for the doors to open to 90° because our added face trim made the doors thicker than just the hinge width.

Hope some of that is helpful.

Aram9012 (author)ColinL52015-09-12

Thank you so much ColinL. That's brilliant. I'm getting started and am gonna make something like yours and PS118 combined with vertical wood pieces in the recesses and then staining dark brown. It's good that the thickness doesn't make it too heavy for the hinges to support, I was thinking of having 4 hinges/each door just in case. Thanks again, I will post when I'm done.

PS118 (author)ColinL52015-05-18

Those look fantasic!

DaJudge51 (author)2016-05-31

I like the design, and I like your attitude. I'm not as smart as you, but I might have a little more experience with wood. All in all, I think your plan is doable and nicely presented. Thanks.

BallabhY (author)2016-05-15

Awesome build there! Being an ex-IT manager, i appreciate what you did despite it not being your main job. I am building a house and a single garage with it, plan to put z-wave controllers along, thanks for the amazing writeup!

JimS176 (author)2016-04-06

I notice no diagonal bracing on the doors. How are they doing now? Still square?

Jeffr56 (author)2015-09-27

pbates123 (author)2012-02-05

Nice Job PS118. You have a very attractive set of doors there! I particularly like the window re-purposing.

As you know "hind site is...." and like you, I have learned from many mistake in the past so not to dis your work I have a couple of suggestions for anyone considering building there own.

Toward the end you show the post sitting directly on the concrete. A sign your concerned about it too. At your typical box hardware store you can purchase a 1in. square galvanized post base.

Like this: http://www.lowes.com/pd_108719-72913-ABA44Z_0__?productId=3006427&Ntt=simpson+strong+tie+post+base&pl=1&currentURL=%2Fpl__0__s%3FNtt%3Dsimpson%2Bstrong%2Btie%2Bpost%2Bbase&facetInfo=

Cut off the post short and slide the block underneath. The reason is the lumber will absorb water from the concrete and the wood will rot. Using Pressure treated lumber would help in this regard but it is still not the best.

Next, even though the door frame doesn't touch the ground "now" they may sag in the future. It looks like you used Douglas Fir or Pine (just a guess) in the frame neither of which is particularly resistant to water damage. It maybe wise to make the frame a little shorter by maybe an inch or even two and let the clapboards fill the gap. That way if the door sags you can trim the clapboard without reducing the strength of the frame and still clear the ground. That keeps the frame clear of water and away from critters.

Many years ago much if not most of the lumber was kiln dried and therefore it shrank very little over time. Today most wood unless specifically purchased as such is not dried. I purchased 8" dog eared redwood fencing, then it was very close to 8" but today it it's more like 7 1/2" to 7 5/8" and redwood normally shrinks from end to end(dimensionally) rather than side to side. Most other woods shrink from side to side more than end to end.

What is the point? I would butt the clapboards together rather than leave a gap or at the most I would leave a nails width between the boards. When the boards shrink the gap will still be covered.

By the way I grew up in and around the mountains and I really took to heart the outline where you mentioned why you move to the area!! Great work!!

hivolt (author)pbates1232015-09-13

Another way to isolate the wood posts from the concrete floor is to nail a piece of vinyl floor tile to bottom of the post. This method is nearly invisible. Just be sure to use rust proof nails (stainless steel, hot dipped galvanized, etc.)

pbates123 (author)hivolt2015-09-13

Hello Hivolt,

I have never tried that. Any "Barrier" is better than none although I tried Galvanized Sheet stock and the critters still got to it. Thanx for the suggestion!

ColinL5 (author)2015-09-12

Forgot to mention that we did add an extra hinge in the middle, so 3 hinges on each door to help carry the weight. But overall they are not heavy doors.

Oliver Levenson (author)2015-04-28

I recently bought a new house, but the doors of the house are almost damaged...and they need repairing but i do not know where can i get a fine [url=http://doorslasvegas.com/]Door Repair[/url]...some people suggest me door repair service in las vegas...but i am not satisfied with their service...any other place for doors repairing???
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cooked1 (author)2013-11-20

Nice report, I picked up a few ideas and managed to avoid the mistakes you said you made, was also resigned to the fact that I was going to have to fit and refit the doors. My entry is somewhat wider , so from the beginning I tightened galvanised wire between the upper hinge side and the bottom middle side (if that makes sense). Made all the difference.

togo1919 (author)2013-05-20

Beautiful doors!

1chunkymonkey247 (author)2013-05-15

In the case of wanting to use the doors to enter and exit, what would you suggest to use to cover it up and look more presentable

rpace1906 (author)2013-03-01

This is way awesome! I'm trying to find a place that does garage door repair in Minneapolis, and was wondering if you had any suggestions as to what to look for when selecting someone who does garage door repair?

brady.fowler (author)2012-06-04

I bought carriage "look" doors for my house, love them and the way they look. Now that I am remodeling my barn I wanted a set of doors to match. My garage door is 9' by 11' and hard to find any good looking doors. I searched and searched the Internet for door plans or ideas, very little help. Long story short I decided that worse case I would be out lumber and built my own.

They are massive and heavy but I am pleased.

minstrel458 (author)2012-04-02

Thank you so much for this post. As you so aptly noted in your tutorial, DIY plans for Carriage Doors on the internet, are NON-existent. I've been looking for some on and off for months. You've helped me clarify my thinking and have provided some excellent explanations. Thanks SO much!!!

PS118 (author)minstrel4582012-04-02

Thanks, I appreciate that! :)

Uptonb (author)2012-03-02

Congrats on being a finalist, and good luck!

sandisroses (author)2012-02-13

Perfect. My 1908 house & garage thank you. I thank you.

riff raff (author)2012-01-12

Nice instructable. You got my vote.

Two things come to mind; the use of CCA or "Yella Wood" for the 4x4's would eliminate the need for tar, and the use of safety cable inside garage door springs GREATLY reduces the danger of them injuring anyone (or just replace them every 20 years or so...they don't fail that often).

Rob O (author)2012-01-08

Very Nice! I learned a few things. I like how you pointed out how things could be done differently for different results. The real question is... Where the heck do you live?? It looks majestic!

PS118 (author)Rob O2012-01-09

Since you're curious, this is a small valley in the Rocky Mountains. About 5000 feet elevation.

A little chilly in the winter, but even so I'm enjoying it more than smog and suburbia. :)

cblair1 (author)2012-01-08

My home is Victorian from top to bottom inside and out except our detached two story garage, you just finished our total Victorian theme redo!!! Thank you so much!

PS118 (author)cblair12012-01-09

Victorian? Very cool!! Post pics. ;)

macwhiz (author)2012-01-07

For an opener you could use a set of electronic gate openers

PS118 (author)macwhiz2012-01-09

Good idea.

vincent7520 (author)2012-01-08

great ! …
where do I vote ?…

PS118 (author)vincent75202012-01-09

Sorry about that. The moderators only just barely added it to the contest today. Now there should be a vote button on the top of the page.

Alternatively, it's on the contest page as well.
https://www.instructables.com/contest/shopbot/?show=ENTRIES&sort=RECENT

Thanks for the vote!!!

pegasus50 (author)2012-01-09

Nice Work! I've been researching a similar project for my town house's one-car garage that I'm hoping to convert into a workshop. I'll be attempting to "recycle" the current steel "flip' style door for added security and because the frame will save me some time. Also thanks for the link you included which had some good insights. Hoping your's will hold up well...it looks a little chilly out there where you are!

inkdan (author)2012-01-09

Thanks. Very good.

kwhitacre (author)2012-01-09

Well done. I enjoyed your writing style. If I ever have to replace my very large door I want to make it look like fake carriage doors, but be from wood as you have done. Thanks for the good read.

I want to actually build a gate for my deck and your doors are helping me think about my gate. Thanks.

PaulaTx1 (author)2012-01-08

Thanks for the detailed instructions and photos. You have inspired me to try this project! I think I will try insulated windows to help keep cooling costs down.

tuppence (author)2012-01-08

Great job and a great read

raviolikid (author)2012-01-08

Fun description of your project. I love the pictures and your comments.

I hope you win!

emmakrazy (author)2012-01-08

Getting ready to build an earthship home and this is just what I need for the finishing touch to my garage doors! Thanks for sharing!

WoundedEgo (author)2012-01-08

Elegant.

zomfibame (author)2012-01-07

I like the way you used the windows in the doors. nice.

l8nite (author)2012-01-06

really nice build

mikeasaurus (author)2012-01-06

These look great, thanks for sharing the story!

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