Garage door - part 2

by brae  

Continuing work on the garage door. On the backside, I found the 3D printed hinges to be rather delicate. During the first dry fit, I popped one off completely (luckily, I had a replacement panel), but I split another one while fitting the screws. I'm planning to use metal hinges instead since I don't trust myself to not break these after it's all put together, so it was back to the drawing board on aligning the door with the track.

I've used a Timberbrook garage door before (a wooden residential door), so I am using that as a guide. It has rollers on the sides that fit inside a wooden track.

Since I'd like to use the 3D printed track detailing, I can't add rollers and will have to use the bolts as recommended. But, since I'm replacing the plastic hinges, they won't fit or align the same way. This actually works in my favor since my plan would make the front of the garage door closer to flush with the front of the track, which will be easier for me to fit to my building.

Using the spare eliminated fifth panel as a test piece, I drilled a pilot hole in the side of the door panel and then added a bolt.

I determined the length needed to fit in the track without binding or slipping and snipped the head off. This seemed like it would work well, so I moved on to the actual panels.

I shaved off the plastic hinges and filled with putty as needed before adding thin styrene patches for stability.

I used white putty to fill in the gaps where the parts join. After an initial primer coat, I could better see where I needed to fine tune the putty application. Filling the gaps was never going to be perfect, but I could try to make them look less like "errors" in building with the putty.

After sanding, I touched up the primer and sprayed the fronts dark brown.

I used some really old spray paint, and it gave me an orange peel texture, which on a new piece would mean sanding and sanding and sanding. On an old piece, it will save me some time and work in my favor. I didn't necessarily want a shiny finish, but there are so many layers still to come it doesn't matter.

More to come....

3 comments

Comment from: Marilyn [Visitor]  
I love your techy posts. Perverse really as it will not be anything I will ever tackle but I love the thinking processes and the solving problems in this game and can enjoy that vicariously.
05/06/20 @ 10:25
Comment from: ann [Visitor]
Nice work. So much a part of what we do requires problem solving and getting things to work and to fit. You do that very well.
05/07/20 @ 14:00
Comment from: brae [Member]
Thank you!! :>> I do enjoy putting on my engineering hat. :yes:
05/10/20 @ 10:19


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