Custom Made Roller Doors: Australian Prices, Sizes & Guide

Looking for a roller garage door that actually fits the opening, matches the façade and won’t blow out the budget? Custom-made rollers now start at roughly $750 for a basic single manual unit and run to about $3,800+ for a double, wind-locked, motor-driven door. Every millimetre, every Colourbond shade and every wind rating can be tailored and delivered anywhere in Australia, so there’s no need for clumsy fillers or expensive structural tweaks.

This guide arms Australian homeowners, renovators, shed builders and small business owners with all the facts before they click “order”. You’ll see clear size and price tables, learn how custom doors differ from hardware-store stock, measure accurately, tick the compliance boxes, compare automation options, and decide whether to DIY or call the pros. By the end you’ll know exactly what a fair quote looks like and how to organise a door that rolls smoothly from day one.

How Custom Roller Doors Differ From Off-The-Shelf Options

A “custom-made” roller door is built only after you supply the exact opening size, colour choice and wind rating. The manufacturer rolls and cuts each slat to the millimetre, matches your preferred Colourbond finish, adds the nominated lock or motor package and then ships the lot direct to site—ready to hang. A shelf door, in contrast, is produced in preset widths (e.g. 2400 mm or 3000 mm) and heights, usually only in four to six colours, and it’s up to you or your installer to make the hole fit the door.

Why many Australians are opting for custom specification:

Precise fit means tighter weatherseal, fewer draughts and less daylight sneaking in
No ugly infill panels; the façade looks as though it was drawn that way
Built for your wind region or BAL rating, so compliance headaches disappear
Factory-cut curtain gives better weight balance, increasing spring life and motor efficiency
Upgrades such as smartphone control, keyed-alike cylinders or wind-locking can be added at build time

Potential trade-offs to consider:

Lead time: 5–15 working days instead of “pick it up today”
Measurement responsibility sits with the buyer—order wrong, and the door is yours
Returns are limited; most factories allow ±5 mm tolerance only for warranty claims

Key Components & Build Quality

Quality custom made roller doors use Bluescope Colourbond or Zincalume slats pressed from 0.4–0.6 mm steel. Look beyond the curtain:

Heavy-duty aluminium drum supports smoother roll-up and reduces sag on spans over 3 m
High-tensile counterbalance springs (minimum 15,000 cycles) cut lifting effort
Nylon-lined guides and PVC weatherseal hush rattles and keep water out
Wind-locked pins or double-track guides stop blow-outs in Region C & D sites

These parts add a few kilos but give a quieter, longer-lasting door than the thin drums and galvanised springs found in budget imports.

Manual, Chain-Drive or Fully Automated?

Manual spring-balanced: cheapest, no power needed, but you’ll lift ~15 kg each morning
Chain-drive: suits farm sheds or 4 m+ industrial openings; slower yet reliable and easy to repair
Electric opener: the popular choice for homes—ATA entry models from ~$400, Merlin mid-range around $650 and Grifco heavy-duty for oversized doors at $900+; add $60–$90 for Wi-Fi modules

Factor in a standard 10 A GPO within 1 m of the drum, and remember all motorised doors must include an auto-reverse safety stop to meet AS/NZS 4505.

Roller Door Sizes Explained: Standard Ranges & True Custom Limits

Before you open the configurator it helps to know what “standard” looks like and where a true bespoke door can push the boundaries. The tables below show the dimensions most factories keep tooling for, followed by the absolute minimum and maximum spans typically offered by Australian manufacturers.

Application	Common Clear Opening Width (mm)	Common Opening Height (mm)
Single garage (sedan/ute)	2,400 – 3,000	2,100
Double garage	4,800 – 5,200	2,100 – 2,400
Farm / garden shed	3,000 – 3,600	2,400 – 2,700
Semi-commercial shopfront	4,500 – 6,000	3,000 – 4,000
Light industrial / warehouse	6,000 – 8,000*	3,600 – 5,100*

*Requires heavier-gauge curtain and chain or Grifco motor.

Typical custom limits:

Minimum span: 800 mm wide × 700 mm high
Maximum domestic span: 5,600 mm wide × 5,100 mm high
Semi-commercial engineered span: up to 8 m wide (height permitting)

Clearance You’ll Need Around the Door

Dimension	Domestic Door	Wind-locked / Semi-commercial
Headroom (top of opening to ceiling)	400 mm	450–500 mm
Sideroom (jamb to wall/obstruction)	75 mm each side	110 mm each side
Backspace (opening to first obstruction inward)	400 mm	500 mm

Getting these wrong is the number-one cause of expensive order changes, so measure twice.

How to Measure Like a Pro

Measure width in three places—lintel, mid-height and floor. Record the smallest.
Measure height at both jambs and the centre. Again, note the smallest.
Check floor for fall; anything over 10 mm may need a taper strip or adjustable bottom seal.
Inspect lintel for bowing. More than 5 mm deflection should be packed out before install.
Confirm you have the minimum head, side and back clearances from the chart above.
Photograph the opening and jot down wind region (A, B, C or D) for the order form.

Small & Narrow Roller Doors for Garden Sheds

Mower, quad-bike and pool-pump sheds often need openings just 1 m – 1.5 m wide. While custom made roller doors can be produced down to 800 mm, expect a 10–15 % price premium because the factory must reset cutters for the tiny drum. Alternatives include aluminium roller shutters or off-the-shelf shed doors from hardware stores, but these rarely match the strength or colour palette of a full-blown garage door.

Extra-Wide, High-Clearance & Wind-Rated Doors

For machinery sheds, caravan ports or Region C & D coastal blocks you may need 4 m+ heights or wind-locked guides. Manufacturers answer with stiffer 0.6 mm slats, oversized drum wheels and steel wind-brace channels. Remember that every metre you add increases curtain weight exponentially (Area = width × height), so budget for a chain hoist or heavy-duty motor once the door tops ~25 m².

Australian Price Breakdown: What You’ll Really Pay in 2025

How much will a custom made roller door set you back this year? The short answer is that square-metre area drives the bulk of the figure, then every upgrade—steel grade, colour, wind kit, motor, freight—moves the needle. The table below shows ball-park supply-only pricing pulled from half-a-dozen leading manufacturers and updated for Q3 2025.

Door Spec (Colourbond steel)	Size (W × H)	Wind Rating	Operation	Typical 2025 Price*
Single garage – manual	2400 mm × 2100 mm	Region A	Spring-balanced	$850 – $1,100
Single garage – motorised	2400 mm × 2100 mm	Region A	Merlin MT120EVO	$1,350 – $1,800
Double garage – wind-locked + motor	4800 mm × 2100 mm	Region C	ATA GDO-9v4	$2,600 – $3,400
Extra-height caravan door	3000 mm × 3000 mm	Region B	Manual	$1,900 – $2,400
Semi-commercial farm shed	6000 mm × 4000 mm	Region B	Chain drive	$3,800 – $5,500
*Supply-only, metro delivery included where noted by supplier.

Key cost drivers to keep in mind:

Door area: price scales roughly Base rate × (width × height).
Steel gauge: upgrading from 0.45 mm to 0.6 mm adds 6 – 12 %.
Wind kit: wind-locked guides and stiffer slats cost $180 – $600 depending on span.
Colour surcharge: non-standard or powder-coated finishes add $80 – $250.
Automation: openers range from $400 for entry ATA units to $950 for Grifco heavy-duty, plus $60 – $90 for Wi-Fi modules.
Delivery zone: most brands ship metro free; regional freight is a sliding scale based on pallet length.

Compared with warehouse-stock doors (think Bunnings special orders at $700 – $900), a custom unit is usually 10 – 20 % dearer on paper. Factor in the cost of infill timbers, extra flashings and labour needed to “make the opening fit” and that gap often disappears. Add to that the energy you’ll save from a tighter seal and the argument for bespoke gets stronger still.

Hidden & Ongoing Costs

Sticker price isn’t the whole story, so budget for the following line items before you click “pay”:

Freight surcharges: remote NT, North QLD and WA country routes can add $250 – $600 per door.
Professional installation: licensed installer labour averages $300 – $900 depending on size, height and opener wiring.
Annual servicing: lubricating springs, checking balance and replacing weatherseals every 5 – 7 years comes in at $150 – $250.
Power bills: a modern opener draws <1 W in standby, translating to about $3 a year; negligible but worth noting for off-grid sheds.
Insulated curtain upgrade: PU-filled slats run roughly 25 % more and add weight—meaning you may need the next-grade motor.
Future smart-home add-ons: extra remotes, keypads or HomeKit bridges are usually $50 – $180 each.

Run these numbers through your own scenario and you’ll land on a realistic all-in figure—no nasty Monday-morning surprises when the invoice lands. With that groundwork laid, let’s look at the longer-term material and colour choices that influence appearance, longevity and running costs.

Materials, Colours & Insulation Choices

The steel and finish you nominate are every bit as important as the size when speccing custom made roller doors. Most Aussie factories work with Bluescope Colourbond (0.45–0.6 mm) for everyday homes and bare Zincalume for sheds that will be painted later. In marine or heavy-industrial zones you can step up to Colourbond Ultra and stainless fixings to keep rust at bay for decades.

Colour is where the fun starts. Current top sellers are split between modern neutrals and time-honoured classics:

Contemporary favourites: Basalt, Monument, Surfmist, Shale Grey, Woodland Grey, Dune, Windspray, Night Sky, Classic Cream, Evening Haze
Classics still going strong: Paperbark, Pale Eucalypt, Manor Red, Ironstone, Cottage Green

Because every slat is coated before roll-forming, colour runs right to the cut edge—chips and scratches are far less obvious than with after-market spray jobs.

Insulated curtains use polyurethane-filled twin-skin slats that lift the door’s thermal performance to around R-1.4. Expect a 3–4 dB drop in road noise and a noticeably cooler garage on scorcher days. The trade-off is an extra 15–25 % in weight, so you’ll likely need the next-size spring or motor upgrade.

Design tips for kerb appeal:

Match the door to guttering and fascia for a seamless look
Contrast with brickwork on heritage homes to highlight the opening
Ask for colour-matched guide tracks and bottom rails; small detail, big impact

Sustainability & End-of-Life Recycling

Australian steel already contains up to 25 % recycled content and is 100 % recyclable at the end of its life. When your roller door hits the 20-year mark, unbolt the curtain, roll it tight and drop it at any scrap-metal yard—about $80 / tonne is typical. Bluescope’s low-VOC paint lines, plus biodegradable grease options for springs and bearings, keep indoor air quality in check. Guides and drums are mostly aluminium, which a recycler will also happily take, turning yesterday’s door into tomorrow’s washing machine or bike frame.

Measuring, Ordering & Installing Your Custom Roller Door

Getting the tape out is the moment that separates a perfect fit from an expensive headache. Unlike shelf doors that allow a little wiggle room, custom made roller doors are manufactured to the millimetre, so accuracy is everything. Before you fire up the online configurator, run through the checklist below.

Measure structural opening width and height three times; write down the smallest figures
Confirm headroom, sideroom and back-space clearances from the previous chart
Identify your wind region (A–D) and any BAL requirement if you’re in a bush-fire zone
Check there’s a 10 A power point within 1 m of the drum for an opener
Note delivery access: can a 9 m rigid truck reach the site, or do you need a ute-drop?

Once the numbers are solid, the ordering workflow is dead simple:

Enter width and height to the millimetre
Pick a Colourbond shade or Zincalume
Select wind rating upgrade if required
Choose manual lock, chain hoist or motor package (and Wi-Fi module if desired)
Add delivery address and preferred install date

Most Australian factories quote 5–15 working days for manufacture. Metro deliveries usually follow 1–3 days later; regional and remote runs can stretch to 7–10.

Planning a DIY install? These are the core tasks and tools:

Tools: 10 mm socket set, spanners, tek gun, silicone, tape measure, two ladders
Mount wall brackets square and level
Fix guide tracks, then hoist the drum onto the brackets
Hang the curtain and tension counter-balance springs (follow the supplier’s turn chart)
Clip on the bottom rail, fit stops and test manual balance
Mount opener, set travel limits and pair remotes

Safety first: springs are under serious tension—wear gloves, lock ladders and always have a second set of hands when lifting the drum or curtain.

Commissioning & Long-Term Maintenance

After the first week of operation, run a quick shakedown:

Check all fasteners for movement
Re-test auto-reverse with a 40 mm timber block in the doorway

Annual upkeep is straightforward:

Hose out and dry the guides, wipe the curtain clean
Lubricate nylon rollers, spring bearing and chain (if fitted) with non-silicone spray
Test manual balance; the door should stay put at half height
Inspect weatherseal for cracks and replace if light shows under the rail

Common niggles and quick fixes:

Door jerks: usually grit in the guides—clean and re-lubricate
Opener won’t close: realign photo-eye beams or remove debris
Remote range drops: swap the battery; if no joy, re-code or relocate the antenna

Follow these simple routines and your new roller door should glide happily for 20 years or more.

Compliance, Safety & Australian Standards

Ordering a roller door that suits the hole is only half the job—you also need to satisfy regulators, insurers and the sparky doing the final sign-off. In Australia, the benchmark test for roller doors is AS/NZS 4505, which sets out minimum wind load resistance for Regions A through D. Reputable manufacturers test each door size in a NATA-accredited lab and supply a data sheet showing the ultimate and serviceability pressures; keep that PDF with your building file.

The National Construction Code (NCC 2025) leans on the same standard and adds bushfire performance requirements. If your site is BAL-12.5 to BAL-40, steel curtains and aluminium guides usually tick the box, but confirm the door is labelled “BAL-compliant” before you pay the deposit.

Motorised doors bring their own rules. To pass an electrical safety inspection the opener must include:

Auto-reverse within 0.75 s of meeting a 40 mm obstruction
Manual release cord reachable from ground level
Photo-eye or force-sensing edge for any opening onto a public footpath

Finally, check the paperwork. Most custom made roller doors carry a 7–10 year curtain warranty and 2–5 year motor warranty. Using non-approved lubricants, drilling extra holes in the drum or skipping annual maintenance can void both.

Insurance, Council & Strata Considerations

A new roller door rarely needs a DA, but some councils insist on a façade-change notice if the colour shifts from the original. Strata committees may ask for proof of wind certification and an installer’s completion form. Supplying these documents can shave a few dollars off your building insurance premium, while failure to do so could see a storm-damage claim knocked back. Keep digital copies of the compliance certificate, invoice and installation photos in the cloud for easy retrieval.

Where to Buy Custom Roller Doors in Australia

Unlike stock doors you can throw in the trolley, a made-to-measure roller door usually comes from a specialist that can cut, balance and freight a one-off build. The snapshot below compares the five most common buying channels Australians use in 2025.

Supplier	Ordering Method	Typical Lead Time	Delivery Reach	DIY Resources
Doorsupply	Online configurator	5–15 working days	Nationwide (free metro)	PDF guides, phone support
Steel-Line	Showrooms + phone	2–3 weeks	Nationwide	Supply-and-install packages
Stratco	In-store special order	3–4 weeks	Metro & regional depots	Limited PDFs
Bunnings (Special Orders)	In-store kiosk	4–6 weeks	Stores only (no direct site drop)	Basic install sheet
Local fabricator	Site visit & quote	Varies (1–6 weeks)	Local region	Bespoke advice onsite

Pros of buying online: sharp pricing, immediate quotes, and you control every spec. Downsides: you’re on the hook for measurements and installation unless you book a separate tradie. Local showrooms let you touch samples and bundle installation, but overheads usually add 10–20 % to the ticket and rural delivery can still sting.

Questions to Ask Any Supplier Before You Commit

Can you provide an AS/NZS 4505 wind-rating certificate for my exact size?
What happens if manufacturing runs late—do you compensate or upgrade freight?
Which opener models are factory-compatible and can I add Wi-Fi later?
How long will you stock spare slats, remotes and springs?
Is the door insured in transit and who handles claims for transport damage?
Do you offer phone or video support on install day if I run into trouble?
Asking these up-front keeps surprises to a minimum and helps you compare quotes on more than just sticker price.

Quick-Fire FAQs

Are custom roller doors more expensive than sectional doors? On like-for-like openings they’re often 5–10 % cheaper; sectionals gain insulation and style options.
How long does Colourbond paint actually last outdoors? Factory coating routinely exceeds 20 years before noticeable fade; wash yearly to keep salt off.
Can I replace an old tilt-a-door with a roller door? Yes—provided headroom is ≥400 mm and the opening is square; patch existing jamb holes.
Is DIY installation legal in every Australian state? Installing the door is fine; wiring a new GPO must be handled by a licensed electrician.
What’s the life expectancy of a roller door spring? Standard springs are rated 15,000 cycles—roughly 10–12 years of daily use—then swap them.
How can I quieten a rattling roller door? Clean the guides, apply non-silicone spray, re-tension the spring and replace worn weatherseals.
Can a roller door be insulated after installation? Clip-on bubble-foil liners help, but true PU-filled insulation requires a new curtain.

Ready to Measure Up?

Custom sizing wipes out ugly infills and lets your roller door look, seal and perform as if it grew with the building. Remember, though, every millimetre adds dollars: width × height is the base cost, wind upgrades push the price for cyclonic sites, and the motor you pick determines day-to-day convenience. Measure accurately, tick the compliance boxes and you’ll protect both your warranty and your insurance cover.

Quick recap before you grab the tape:

Size first – confirm clear opening, headroom, sideroom, back-space
Know your site – wind region, BAL rating, power outlet position
Decide on operation – manual, chain or motor, plus smart-home extras
Lock in colour and steel grade to match the façade and environment

Ready to turn numbers into a firm dollar figure? Fire up DoorSupply’s instant quote tool or chat with the local team at Doorsupply for advice that’s as custom as your new door.

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