How to Repair Cracked Garage Door Panels DIY - Tips and Steps

How to Repair a Cracked Garage Door Panel

A cracked or broken garage door panel can be an eyesore and safety hazard. Thankfully, repairing a cracked garage door panel is a DIY project that most homeowners can tackle themselves. With a few tools and some basic handyman skills, you can have your garage door looking like new again in no time.

Assessing the Damage

The first step is to assess the damage to determine how extensive the cracks are. Minor cracks or splits in the panel may be able to be repaired with caulk or filler, but larger cracks will require replacing sections or the entire panel.

Inspect the panel closely to see if the crack goes all the way through the panel. Also check if the crack is causing the panel to come apart or become warped. If so, replacement will be needed.

Safely test the door's operation by lifting manually. If the door sticks, binds, or does not move smoothly, the damage may be more serious.

Gather Supplies

Once you've determined that you can repair the panel yourself, gather the necessary supplies. Here's what you'll need:

• Replacement panel or panel section
• Power drill
• Impact driver
• Screwdrivers
• Pliers
• Hammer
• Putty knife
• Caulk/filler
• Sandpaper
• Paint/primer

The specific tools and materials required will depend on the extent of the repair job. For minor cracks, you may only need caulk and paint. For full panel replacement, you'll need new sections cut to size, screws, and tools for removal of the damaged panel.

Remove the Damaged Panel

If the entire panel needs replacement, you'll first need to remove the old cracked panel. Start by disengaging the opener and manually raising the door a couple feet (have helpers for heavy doors). Place locking pliers under the track to prevent the door from falling.

Using a power drill with a driver bit, remove any screws, bolts or rivets securing the panel. You may need to drill out the heads if they are stripped. Apply penetrant beforehand if necessary. Carefully pry off the panel with a putty knife or screwdriver. Remove any remaining screw studs.

For minor cracks, you can fill without panel removal. Just thoroughly clean and sand the area first.

Prepare the New Panel

If replacing the full panel, measure and cut a new one to size out of fresh garage door panel stock. You can also purchase pre-made replacement panels in various sizes. Use galvanized screws to assemble sections if needed.

Make sure the new panel matches the dimensions of the old one for proper fit. Test fit the panel first before permanently attaching.

For cracks, apply caulk/filler as needed per manufacturer instructions. Allow proper dry time.

Install the New Panel

Once prepped, install the new intact panel or cracked panel. Attach hinges and hardware to the new panel first if replacing the full unit.

Hoist the panel into place, aligning the edges properly so it sits flush with no gaps. Drill pilot holes and reattach with garage door screws/bolts. Apply garage door sealant or caulk around the edges for weatherproofing.

Reconnect the door arm and opener. Check that the door opens and closes properly without scraping or hitting the new panel. Activate the opener and test a few full cycles.

Finish Up

With the hard part done, finish the repair job by refinishing the new panel. Apply primer and paint to match the rest of the door. Allow proper dry time in between coats.

For minor cracks, smooth caulk/filler flush with the panel. Once dry, sand the area to feather in before painting. Be sure to cover surrounding areas when painting to avoid splatters.

Clean up the work area once completed and remove any pliers or locks. Test the door opener several times to ensure the door runs smoothly and properly without any issues after the cracked panel repair.

Tips for Preventing Cracked Panels

To help avoid cracked garage door panels in the future:

• Maintain proper lubrication - Lubricate rollers and hinges to prevent sticking.
• Inspect weatherstripping – Repair or replace worn weatherstripping to avoid wind damage.
• Test opener sensitivity – Adjust forces so door doesn't hit ground hard when closing.
• DIY visual inspection – Check for early cracks, dents or sagging.
• Consider upgrades – Upgrade to sturdier door models resistant to impacts.
• Practice opener safety – Don't let children play with or under operating door.
• Be aware of surroundings – Keep area around door clear to avoid accidental hits.

Performing routine maintenance and taking measures to prevent cracks will help your garage door panels stay in good condition for longer. But even if a crack does develop, this is a DIY repair project most homeowners can do themselves.

When to Call a Professional

In some cases, it's best to call a professional garage door technician for panel repairs:

• If the damage is severe or garage door is unsafe to operate
• For tricky access or high garage doors
• If the door binds, scrapes or doesn't operate smoothly
• For precision work like reinforcement or alignment
• If you don't have the right tools or DIY skills
• For full garage door replacement rather than panel repair

A professional can assess the root cause of the damage and perform structural repairs. They have the expertise to identify and fix issues you may miss. This can save you time, hassle, and money versus DIY trial and error.

For most cracked garage door panels however, with a little time and effort, homeowners can tackle this repair themselves without the expense of calling a pro. Just take all necessary safety precautions when working at height around the heavy garage door.

FAQs

How can I tell if I need to replace the entire panel or just patch a crack?

Inspect the extent of the damage. Minor cracks and splits may be repairable with just caulk or filler, but large cracks that go all the way through the panel or cause warping likely mean the entire panel needs replacement.

What tools do I need to remove garage door panels?

You'll need basic hand tools like a power drill, screwdrivers, pliers, pry bar, hammer, and ladder. Use a drill with driver bits to remove garage door hardware and screws. Pliers and pry bars help to remove panels or hardware where screws are stuck.

Should I paint the new garage door panel?

Yes, paint the new replacement panel with primer and paint to match the color of your existing garage door. This will help the repair blend in. Be sure to properly prep and clean the new panel first before painting.