AMERICAN SERIES ONE PIECE, DECORATOR GARAGE DOORS SPECIFICATION SHEET	STEP BY STEP PROCEDURE FOR   MANUFACTURING A DECORATOR,   ONE PIECE DOUBLE GARAGE DOOR   USING PLYWOOD PANELS AND   USING AMERICAN SERIES   HARDWARE

Note: Door opening in this example is to be 16' X 7'    Finished door is to be 3/4" narrower than the opening. Frame is to be 1" narrower than opening and the same height as opening. Step 1. Precut your frame members to your desired length. The MATERIAL SCHEDULE for our sample 16' door is shown at bottom right. Step 2. Prenotch the top and bottom frame rails to the exact same size of the 2" X 3" framing members.         Step 3. Lay out frame members on a work table or flat surface.         Note: All pieces need to be on edge except for the three marked (a). Place these flat and fit the end pieces into the notches in the top and bottom rails. Step 4. Nail frame members together. Step 4a. (Optional) For added support and strength an additional " V " brace can be installed as shown in the illustration below. The recommended material is usually two 1" X 6" x required length.         Step 5. Lay precut plywood panels on your completed frame. They will overhang on each end of the door by 1/2". Door width can be trimmed down if so desired.

Step 6. Nail plywood panels to frame. Plywood can be set up 1-1/4" at the top if headroom allows and should be set back 1/4" at the bottom to prevent splintering.         Step 7. Add trim and bottom weatherstrip as desired. Keep door balanced top and bottom. (Truss Rods should also be applied if the door is wider than 10', If desired side weatherstrip and locking hardware can also be installed) Paint door on all exposed sides and edges. Front and Back! Note: IF DESIRED, OTHER MATERIAL, SUCH AS SIDING, FIBERGLASS OR ALUMINUM MAY BE USED IN PLACE OF PLYWOOD. MATERIAL SCHEDULE FOR ONE PIECE WOOD DOOR. For best results all rails and stiles should be Contruction grade Douglas Fir or better. 2 ea. 2 X 3 X 15'- 11" rails w/notched ends 2 ea. 2 X 3 X 7'- 0" side stiles 5 ea. 2 X 3 X 6'- 9" stiles 4 ea. 2 X 3 X 3'- 10 1/2" rails 4 ea. 2 X 3 X 3'- 6 3/4" rails 4 panels 3/8 or 5/8 " exterior type plywood - 4' X 8' 10 doz. galvanized or aluminum 5d or 7d nails 3 doz 16d framing nails DECORATIVE TRIM AS DESIRED NOTE: Lengths may be varied to fit local market's unusual lumber dimensions. 2 X 4 lumber may be used in place of 2 X 3. Adjust calculated weight accordingly. SUPPLEMENT INFORMATION:         For existing openings there are 6 required measurements. This helps to insure that the door fits into the opening properly.