You’ll also need
Measuring tape; pencil; power saw with fence attachment; drill; 25mm spade bit; 12mm and 6.5mm drill bits; spirit level; 10mm and 16mm masonry drill bits; Ramset MultiFit Sieves, Ultrafix Plus and ChemSet M10 Anchor Studs; caulking gun; angle grinder; socket wrench; 125mm galvanised batten screws; nail gun and nails; 10mm plastic packer; flexible gap filler; wood filler; painting equipment; Dulux 1 Step Primer, Sealer & Undercoat; Dulux Weathershield (exterior paint) in Bearsuit.
Note
Prime cut ends of treated pine using exterior paint.
Here’s how
STEP 1 Cut 1 side support to match height of opening. For fixings, mark out 130mm from each end and others spaced evenly between, approximately 600mm apart. Centre holes 60mm from inside edge of support.
STEP 2 Using a 25mm spade bit, drill 15mm-deep holes to countersink nuts on anchors. Switch to a 12mm drill bit and drill through side support.
STEP 3 Place side support against wall and make plumb. Using drill fitted with 10mm masonry bit, drill through holes to mark position on bricks. Remove side support. Switch to 16mm masonry bit. Where bricks are marked, drill a hole 100mm deep.
STEP 4 Insert MultiFit Sieve into holes.
STEP 5 With the tube of Ultrafix Plus fitted in caulking gun, insert nozzle into sieve and inject adhesive. Repeat for remaining holes.
STEP 6 Place side support back on wall. With supplied nut and washer attached, push anchor studs through all holes in side support and into sieve. Turn anchor studs a few times to ensure adhesive is fully mixed. Leave to set.
STEP 7 Tighten 1 nut until sitting in countersunk hole. Use angle grinder to cut off end of anchor stud flush with support. Fully tighten nut using socket wrench. Repeat for all remaining anchor studs.
STEP 8 Cut 1 post to same length as side support. Position on side support so edge of post is flush with inside edge. Drill an even spread of 6.5mm clearance holes through post then attach using 125mm galvanised batten screws, 2 at each point.
STEP 9 Repeat Steps 1–8 to construct and attach side support and post to wall on other side of garage.
STEP 10 Construct bulkhead stud frame to fit between posts. Make overall height of frame the distance from ceiling to top of opening, as specified by the garage door manufacturer. Space studs a maximum of 450mm apart.
STEP 11 With a helper, lift stud frame up into opening. Make level and flush with outside face of posts. Nail to hold, then attach using batten screws.
STEP 12 Measure and cut trim to fit underside of bulkhead. Nail flush with front edge.
STEP 13 Using a power saw with fence attachment, cut lower lining board to width of garage, cutting off grooved edge. (It will have a 10mm overhang at bottom of bulkhead.) Nail 1 end to bulkhead then use 10mm plastic packer to maintain even 10mm overhang of board along trim as you continue to nail.
Tip
Have a helper hold board in place.
STEP 14 Measure and cut remaining lining boards as done in Step 13. Butt each together and nail in position. Measure and cut final lining board to fit in remaining gap.
STEP 15 Fill all gaps using flexible gap filler. Fill nail and screw holes with wood filler, let dry, then sand smooth. Using undercoat, spot-prime filled areas, let dry, then apply 2 coats of exterior paint.
