Insulating a Garage Door - Cheapest Ideas?

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Topic by cpt_hammer posted 01-13-2009 06:45 PM 16401 views 0 times favorited 8 replies Add to Favorites Watch
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6 posts in 5520 days

01-13-2009 06:45 PM

Topic tags/keywords: jig question garage insulation doors tablesaw

I have two one-car garage doors on my house that are sucking away the heat from the house. Especially the master bathroom above it. I was wondering about your solutions to insulating it. You can buy many kits, but they all seam lacking in one or two details. Mostly dimensions large enough, thick enough, or lacking any form of clean appearance.

The dimensions of my garage doors are 9’x7’ with 21”x50”x2” sections (8 sections/door) and are metal panels. Most of the kits come with either 48” wide panels or those that are long enough are only 20” or less in height and in many cases less than 1.5” thick. Also, they do not leave a very finished appearance. The Reflectix material looks ugly and detracts from a finished garage (well, the drywall is up, not painted yet). My idea is to purchase 4 – 4’x8’ sheets of 2” thick insulfoam and cut it to size. However this causes some problems, the only way to get 50” is to cut them along the long axis and then I can only get 2 panel sections. Since I need 16 sections, and at $25 a pop, that would be over $200. I think I can do it for just over a $100.

Here is my idea. I cut 4 sections that are 21” x 48”. I have to dado the bottom and top edges to match the groves in the metal panels. I’ll use my router table for that.

To get the 50” width. I’m going to have 1’x4’ left at the top of the panels as scrap. I take those sections and cut them into 4 – 4” x 21” sections and I’ll dado a 2” wide lip to overlap the 48” panel which will have a matching dado.

My panels also have 3/8” insets for the raised panel look of the doors. I’ll have to reduce the thickness of the Insulfoam by 3/8” using my router and a jig to hold it at the proper height.

Now how do I get the panels in the sections? Well, the sections are 21” in height, however, the metal lip takes away almost a full inch. So I’m thinking of using the table saw and cutting several relief groves in the foam to allow it to flex enough to insert it into the garage door.

I’ll secure the foam using a common bonding caulking such as liquid nails.

Now for the surface? My thought is to primer and paint the exposed surface to match the color of the garage doors. This should make it look very professional and clean.

Overall, does this sound feasible? I know it is alot of work, but it should look nice and provide almost R-8 insulation value to the doors.

View cpt_hammer's profile


6 posts in 5520 days

01-15-2009 05:29 AM

I completed this tonight. I let you know how it works and post some pictures. Just a mental note for future reference. “Wear a mask when working with styrofoam.” When I was done, it looked like a blizzard had occurred in my garage. It’s all cleaned up now, I did notice that the garage is ALOT quieter than it was before. I could hear every car drive by even on the other end of the subdivision. Not anymore.

View PaBull's profile


694 posts in 5480 days

01-15-2009 05:05 PM

Congratulations with this. It is nice to get a job completed.

View dustygirl's profile


321 posts in 5320 days

01-15-2009 05:57 PM

Glad to see you found a solution to your insulating problem.It’s just terrible when cold from the garage keeps rooms in the house cold.

-- Dustygirl Hastings,Ont. Life is too short to sit around doing nothing

View costelr's profile


5 posts in 5245 days

01-15-2009 10:49 PM

It sounds like your idea is a good one. Would like to see photo of the finished project.

Here is what I did with my garage doors. I’m in Florida and the issue was more heat gain than heat loss. I put this insulation in, put an AC unit in there and it is the coolest room in the house! Not pretty, but cool.

From Furniture

View Steve24's profile


1 post in 5200 days

03-02-2009 06:21 AM

If you are looking for something that looks a little better I had great luck with a garage door insulation kit from www.doorinsulationkit.com. I was originally thinking about just picking up some foam and installing it, but I do not like the look of foil or paper. I have been very happy with this so far – There is a major difference in the temperature in the garage.

View ThermaDoor's profile


3 posts in 3453 days

12-13-2013 12:32 AM

Insulate your garage door using thermadoor insulation

View Charlottergreenberg's profile


19 posts in 3413 days

01-22-2014 06:37 AM

This blog contains a number of ideas I have on how to live a BETTER LIFE with LESS … A new insulated garage door can cost thousands.

View ArabianDesertDubai's profile


1 post in 2253 days

03-26-2017 12:09 PM

Thank you for sharing valuable information about your experience about garage doors. I am sure that its sounds feasible.

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