On 3/4/2010 7:14 AM, Hoosierpopi wrote:
The sprinkler near the garage door keeps the bottom panel(s) wetter
than otherwise in South Florida's semi-topical climate. It is time to
replace the door panels once again. They are no longer made of the
world's best lumber - style and rail affairs with a plywood panel
insert.

I agree with Leon on fixing the sprinkler setup.

I had a similar problem (with a 20-year cycle rather than 2-year) and
applied the crowbar to buy the monsterous bit set from MLCS to cut new
rails and stiles from Menards' best 2x4s, and sacrificed a sheet of
their fine (well, maybe not so fine) 1/4" plywood and built a new panel.

I used dowels and Gorilla Glue and if I were doing it today, I'd use
Titebond III and pocket screws.

I gave the panel three coats of polyurethane, sanded the top coat
lightly, primed, and applied latex. It's been five years now, and the
panel still looks like new.

I applied the savings from not buying a new weatherproof door toward a
new B&D variable-speed router and a Jessum router table and lift to do
the routing.

A new door would have been cheaper, but I've enjoyed the new router
setup.

--
Morris Dovey
DeSoto Solar
DeSoto, Iowa USA
http://www.iedu.com/DeSoto/