Custom Size Garage Doors: What They Are, Costs & Options

Custom Size Garage Doors: What They Are, Costs & Options

Custom Size Garage Doors: What They Are, Costs & Options

Every door is made to order, almost no suppliers hold stock doors.

As every garage door opening can be slightly different custom size garage doors are made-to-measure built to the exact Colour, width, height and clearances of your opening, rather than forcing your garage to suit a standard size. They solve tricky gaps, non-standard sheds and tight headroom, while letting you choose the door type (roller, sectional or tilt), materials and colours, wind ratings, insulation and automation to match your home and local conditions. In short: you give the measurements, the door is manufactured to fit—neatly, safely and efficiently—whether you’re replacing an old door or building new.

This guide explains everything you need to know before you buy. You’ll learn who typically needs a custom exact-fir garage door.  While there are standard`' Australian sizes, these are more likely Size breaks where the price from X to Y size are the same.  So a custom door from 2551mm to 2800mm wide are all sold for what is effectively the 2800mm price. There is no additional charge or quicker availability when you order made-to-measure garage doors or `Standard Size' garage doors.

But ii is still important to measure correctly and Doorsupply will show you how, outline door types and finishes suited to our climate, and cover wind-rated and semi‑commercial options for coastal, high-wind and cyclonic areas. We’ll run through opener choices and smart control, real-world costs and the factors that move the price up or down. You’ll also get practical advice on DIY versus professional installation, lead times and delivery access, safety and compliance, insulation and noise, ongoing maintenance, and how to order online for an accurate quote. Finally, we’ll share a quick checklist and tips for comparing suppliers so you can buy with confidence.

Who needs a custom size garage door

If your opening isn’t a neat standard, a custom size garage door is the practical answer. They’re common in renovations and older homes, brick or tilt‑door replacements, sheds and workshops, and laneway garages with tight headroom or side clearances. Custom sizing also solves extra‑tall or narrow bays, and ensures wind‑rated doors fit correctly in exposed locations.

  • Older/architect‑designed homes: Irregular masonry or non‑standard spans.
  • Carport conversions/renos: Replacing tilt doors or altering openings.
  • Sheds/workshops: Narrow or extra‑wide bays that don’t match standards.
  • Extra‑tall clearance: Lifted utes, 4WDs or overhead storage racks.
  • Tight clearances: Limited headroom/side room where standard tracks won’t fit.

Standard sizes in Australia versus made-to-measure

Standard sizes in Australia are pre-set width/height combinations offered by most manufacturers. They’re ideal for new builds designed around them and can be faster and cheaper. But many carports, sheds and older garages don’t match them exactly.

Made-to-measure custom size garage doors are built to your exact opening and clearances—headroom, side room, backspace—so you avoid packers, concrete trimming or visible gaps. They’re the go-to for replacements, extra‑tall or narrow bays, and exposed sites that need wind ratings. DoorSupply makes Australian‑made roller and sectional doors in Melbourne to your measurements in Colorbond or Zincalume, including wind‑locked and semi‑commercial options, so the door fits first time.  All doors are specified in Door size, which includes the overlap, so this is always bigger than the opening width.

How to measure for a custom garage door

Accurate measurements are the difference between a door that glides and one that binds. Always measure the garage opening itself (not the old door), note obstructions, and record everything clearly. A steel tape, level and a helper make it easier. Work in millimetres, and write down the smallest of any repeated measurements. If you’re unsure, DoorSupply’s step‑by‑step PDF guides walk you through the exact checks needed for roller and sectional doors so your made‑to‑measure order is spot on.

  • Width (opening): Measure between the inside faces of the jambs at top, middle and bottom. Record the smallest.
  • Height (opening): Measure floor to underside of lintel at left, centre and right. Record the smallest.
  • Headroom: Measure from lintel underside to the nearest obstruction (ceiling, beams, pipes). Different door types need different clearances.
  • Side room: Measure from each jamb to the nearest wall/pipe/cabinet. Note both sides.
  • Backspace (depth): Measure from the opening back to the first obstruction. Ensure clear travel for tracks or roller curtain.
  • Floor and frame check: Note any floor slope, out‑of‑plumb walls, loose bricks, or uneven lintels.
  • Photos: Take inside and outside shots of the opening and ceiling. They help confirm details for quoting and fabrication.

Types of custom garage doors (roller, sectional, tilt)

Picking the mechanism matters as much as getting the measurements right. Custom size garage doors are typically built as roller, sectional or tilt designs, each suiting different openings, clearances and looks. DoorSupply manufactures Australian‑made roller and sectional doors to your exact size in Colorbond or Zincalume, including wind‑locked and semi‑commercial variants for exposed sites.

  • Roller doors: A single steel curtain that rolls up above the opening. Reliable, low‑maintenance and great for sheds, workshops and wide single bays. Compact at the lintel, and available in wind‑locked/wind‑strong options for high‑wind regions.

  • Sectional doors: Multiple horizontal panels that travel on tracks back under the ceiling. Contemporary street appeal with plenty of profile and colour choice. A strong option for double garages and replacements where you want a neat, tailored finish.

  • Tilt doors: A one‑piece panel that pivots out and up. Minimal internal hardware and a clean, flush look, but it needs clear driveway space while opening. Common in older openings and tight retrofits where a simple swing panel makes sense.  Nore, as tilt doors are difficult to ship, Doorsupply do not supply Tilt Doors.

Materials, colours and finishes made for Australia

Your door’s look and longevity come down to what it’s made from. DoorSupply manufactures custom size garage doors in Melbourne using genuine BlueScope COLORBOND and ZINCALUME steel, purpose‑built for Australian conditions. That gives you a locally made curtain or panel set that fits perfectly, resists the elements and ties in with your home’s exterior palette, whether you’re dressing a street‑facing double garage or a hard‑working shed or workshop.

  • COLORBOND steel: Choose from 20+ popular colours to match roofs, gutters and fascias for a cohesive facade. A smart, low‑maintenance finish that suits modern homes and classic palettes alike.
  • ZINCALUME steel: A clean, metallic look that’s ideal for sheds, semi‑commercial spaces and projects favouring a utilitarian aesthetic.
  • Made-to-measure finish: Precise fabrication delivers tight lines and a neat seal at the jambs and lintel—no awkward packers or visible gaps.
  • Style by mechanism: Roller doors present a uniform ribbed curtain; sectional doors offer crisp horizontal panel lines for a contemporary street presence.

Wind-rated and semi-commercial options for high-wind and cyclonic regions

Australia’s coastal and open-country sites can cop serious wind. If your garage faces prevailing winds or you’re in a high‑wind/cyclonic area, a standard curtain may flex, rattle or blow in. Wind‑rated custom size garage doors add strength and track retention so the door stays on its guides and operates safely when the weather turns.

  • Wind-strong roller doors: Reinforced curtain and components for extra rigidity on exposed sites and wider spans.
  • Wind-locked roller doors: Interlocking side clips keep the curtain engaged in the tracks under load to resist blow‑in/out.
  • Semi-commercial roller doors: Heavier-duty drums, guides and hardware built for larger openings and frequent daily use.

For best results, pair the right wind option with precise measurements, solid jambs/fixings, and Australian‑made COLORBOND or ZINCALUME steel to match your site and style.

Openers, controls and smart home integration

Automation makes daily use effortless. DoorSupply can supply openers from Merlin, ATA, RD Motor and Grifco to suit your custom roller or sectional door. Match the unit to the door’s size, weight and duty cycle, especially on wind‑rated or semi‑commercial builds. Controls typically include handheld remotes and an interior wall control, with optional accessories and the ability to add app‑based control on compatible models—confirm at quote time.

  • Capacity and fit: Match the opener to door type, weight, width and track layout.
  • Connectivity: If you want app control, ask for a compatible unit and module at quoting.

What custom size garage doors cost in Australia

Because they’re built to order, the price of custom size garage doors depends on door type (roller, sectional or tilt), exact dimensions, material/finish and wind rating, plus whether you include automation. Buying online from an Australian manufacturer like DoorSupply keeps pricing competitive, and free door‑to‑door delivery to most main cities across Australia helps the bottom line. DIY installation can reduce labour outlay; professional fitment adds install and old‑door removal. To compare quotes fairly, ask for an itemised, fixed price that clearly lists:

  • Door spec: Type, exact size, colour/finish.
  • Wind provisions: Wind‑strong/locked or semi‑commercial hardware if needed.
  • Hardware/automation: Tracks/guides, locks, opener model, remotes, safety beams.
  • Delivery: To your postcode, access notes and any off‑route charges.
  • Timing and terms: Lead time, warranty details, inclusions and GST.

Price drivers: size, materials, wind rating and extras

Custom size garage doors are priced on specification, not guesswork. Two doors that look similar from the street can be very different underneath, especially once you factor in exact dimensions, steel grade, wind provisions and automation. Use the list below to understand what pushes your quote up or down so you can prioritise what matters.

  • Overall size: More width/height means more steel, heavier hardware.
  • Door type: Sectional doors generally cost more than basic roller doors.
  • Material/finish: COLORBOND colours vs ZINCALUME, premium colours or textures.
  • Wind rating: Wind‑strong/locked or semi‑commercial hardware adds reinforcement.
  • Tracks/guides: Heavier guides, drums and springs for large or frequent‑use doors.
  • Automation: Opener power/duty rating, number of remotes, safety beams.
  • Smart control: App modules, keypads and battery backup increase convenience and cost.
  • Security/locks: Manual locks for non‑automated doors, stronger bottom bars.
  • Seals and weathering: Bottom/side seals and draught kits for better sealing.
  • Delivery/access: Free metro delivery helps; remote/limited access can add fees.
  • Installation: DIY saves labour; pro install includes set‑up and old‑door removal.

DIY installation versus professional installation

DIY is a realistic option for many buyers—especially custom size roller doors—thanks to clear PDF install guides and pre‑configured hardware. It saves labour and gives you full control of timing. That said, accuracy and safety matter: heavier wind‑rated or semi‑commercial doors, and sectional systems with tracks and springs, demand care and experience. Plan power for an opener and confirm access for delivery.

  • DIY suits: Straight, plumb openings; standard single doors; two capable adults; correct tools; you’re comfortable following detailed instructions.
  • Go pro when: Tight headroom/side room; large or extra‑tall spans; wind‑locked/semi‑commercial specs; complex replacements (e.g., old tilt door removal) or you want expert set‑up and commissioning.

Manufacturing lead times, delivery and access

Made-to-measure custom size garage doors are manufactured in Melbourne, so lead times depend on door type, wind rating, colour and current workload; your quote will confirm timing. Delivery is free door‑to‑door to most main cities across Australia, while regional or remote postcodes may take longer or incur freight. Plan access: suitable driveway/height for a delivery vehicle, and have capable people ready to receive a large, bulky item.

  • Note steep drives, narrow lanes, low eaves.
  • Clear a flat, covered storage area on site.
  • Inspect packaging on arrival and photograph any damage.

Compliance, safety and warranties

Compliance, safety and warranties are the three pillars of a trouble‑free custom size garage door. Match the specification to your site exposure (including wind provisions), choose durable Australian‑made COLORBOND or ZINCALUME steel, and install exactly as the manufacturer’s instructions specify. If you’re adding automation, select an opener sized for the door’s weight and duty cycle, and document your measurements, delivery and any approvals so you’ve got a clear paper trail.

  • Compliance: Confirm wind exposure and select standard, wind‑strong/locked or semi‑commercial hardware. Follow the manufacturer’s install guides and use a licensed electrician for power.
  • Safety: Add photoelectric safety beams with automation and set travel/force limits correctly. Treat springs and tensioned gear with care; consider professional commissioning.
  • Warranties: Get written warranty terms for the door, hardware and opener before purchase. Keep proof of purchase and maintenance records; misuse or poor installation can void coverage.

Insulation, weather sealing and noise

Getting comfort right is about more than the curtain or panels. Metal doors conduct heat and sound, so the gains come from smart sealing, correct setup and, where desired, adding insulation solutions to the garage envelope. With a custom size garage door, you can specify the seals you need up‑front and reduce draughts, dust, water ingress and rattle—especially in exposed sites.

  • Bottom seal and threshold: A quality rubber bottom seal plus an optional floor threshold helps bridge uneven slabs and keep water, leaves and pests out.
  • Side and head seals: Brush or vinyl draught seals along jambs and lintel cut airflow, dust and street noise.
  • Pelmet/hood (roller): Enclosing the coil helps limit dust and weather exposure at the head.
  • Set-up and tuning: Correct spring tension, track alignment and opener force limits minimise vibration and operational noise.
  • Wind provisions: Wind‑strong/locked specs reduce flex and rattle during gusty conditions.
  • Insulation options: Consider insulating the garage ceiling/walls and using lined finishes or door insulation kits (where compatible) to improve thermal and acoustic comfort.

Maintenance, repairs and expected lifespan

Regular care keeps a custom size garage door smooth, quiet and safe. With Australian‑made COLORBOND or ZINCALUME steel, simple cleaning and periodic checks go a long way—coastal homes should rinse salt more often. Plan light maintenance each season and a deeper inspection annually, and document what you do to support warranty claims.

  • Wash down: Hose and mild detergent to remove dust, grime and salt from curtain/panels and guides.
  • Hardware check: Inspect and tighten brackets, fixings and track fasteners.
  • Clean, don’t grease tracks: Keep tracks free of debris; lubricate hinges/rollers and moving pivots with a suitable silicone/white‑lithium product as specified.
  • Safety tests: Check manual balance; test opener force limits and photo‑eye beams.
  • Seals: Inspect bottom, side and head seals; replace if cracked or flattened.
  • Wind‑rated gear: For wind‑locked/strong doors, inspect side locks/clips and guides for wear.
  • Repairs: Springs, cables, torsion gear and damaged slats/panels are pro‑only; DIY‑friendly items include remotes, batteries, keypads, lock barrels and bottom seals.

A well‑specified, correctly installed door with routine maintenance delivers a long service life; exposure, usage and duty cycle are the biggest factors in wear.

How to order online and get an accurate quote

Ordering custom size garage doors online is straightforward when you come prepared. The goal is to supply clear, consistent measurements in millimetres and a complete brief so your quote reflects the exact door, wind provisions and automation you need. A few photos and access notes also help the team verify details before manufacture in Melbourne.

  1. Measure accurately: Record opening width/height (smallest of three), headroom, side room and backspace in mm.
  2. Photograph the opening: Inside and outside, including ceiling/obstructions, to confirm fit and track path.
  3. Choose door type: Roller or sectional based on space, look and use.
  4. Confirm wind needs: Standard, wind‑strong or wind‑locked; note if your site is coastal or exposed.
  5. Pick materials/colour: COLORBOND colour or ZINCALUME finish to match your facade or shed.
  6. Select automation: Opener brand/model (e.g., Merlin, ATA, RD Motor, Grifco), remotes, safety beams, keypad, smart add‑ons.
  7. Add essentials: Bottom/side/head seals, manual lock (for non‑auto), pelmet/hood for roller where desired.
  8. Provide delivery details: Postcode, driveway clearance, stairs/lifts, and a contact who can receive bulky freight. Free delivery applies to most main cities.
  9. Request an itemised quote: Size, spec, colour, wind rating, hardware, delivery, lead time and GST clearly listed.
  10. Review and confirm: Double‑check measurements/specs match your site before proceeding to checkout or payment.

Tip: Use the PDF install guides to cross‑check clearances before you finalise the order, especially for tight headroom or wind‑rated doors.

How to compare quotes and suppliers

To compare suppliers of custom size garage doors fairly, line up itemised quotes with identical specs. Confirm the same door type, exact millimetre sizes, wind provisions, material/finish, opener model and accessories. Ask where it’s made, how long it takes, what delivery includes, and get warranties in writing. Consider DIY support versus professional install and after‑sales service.

  • Spec match: Door type (roller/sectional), exact size in mm, COLORBOND or ZINCALUME, and wind rating (standard/wind‑strong/wind‑locked/semi‑commercial).
  • Manufacturing: Australian‑made in Melbourne versus imported; quality of steel and components.
  • Hardware/automation: Included tracks/guides, lock, opener brand (Merlin, ATA, RD Motor, Grifco), remotes, safety beams, smart add‑ons.
  • Lead time: Confirm production timeframe and any colour/wind‑rating impacts.
  • Delivery: Free door‑to‑door to most main cities, regional surcharges, access requirements, damage claims process.
  • Installation: DIY guides/support, availability/cost of professional install and old‑door removal.
  • Compliance: Wind exposure suitability and clear installation instructions; electrician for power.
  • Warranties: Written coverage for door, finish, hardware and opener; service response and parts availability.
  • Seals/extras: Bottom, side/head seals, pelmet/hood, keypads—itemised so you’re not comparing “bundles.”
  • Terms: Measurement sign‑off, variations, cancellations and GST clearly shown.

Custom door buying checklist

Before you press buy, run this quick checklist to avoid measurement mistakes, missing parts and delivery surprises. It covers the essentials so your Australian custom size door arrives ready to install.

  • Measurements in mm: Width/height (smallest of three), headroom, side room, backspace.
  • Door type: Roller/sectional/tilt to suit space, look and use.
  • Wind rating: Standard, wind‑strong, wind‑locked or semi‑commercial as site requires.
  • Materials/finish & sealing: COLORBOND or ZINCALUME; bottom/side/head seals; pelmet/hood (roller).
  • Opener/controls: Correctly sized model (Merlin/ATA/RD Motor/Grifco); remotes, keypad, safety beams, smart add‑on.
  • Delivery/access/assurances: Postcode, access notes; written lead time and warranties.
  • Install/quote: DIY or pro; itemised, GST‑inclusive price with measurement sign‑off.

Frequently asked questions

Here are quick answers to the most common questions about ordering custom size garage doors online in Australia.

  • Can you get any size made? Yes—made-to-measure to your millimetres, with feasibility confirmed in your quote.
  • What measurements are required? Opening width/height, headroom, side room and backspace in mm, plus photos.
  • How long will it take? Lead times vary by door type, colour and wind rating; confirmed on quote.
  • Do you deliver nationwide? Free door-to-door to most main cities; regional areas may incur surcharges.
  • Is DIY installation realistic? Yes for many roller doors with PDF guides; complex jobs suit pros.
  • Which openers are compatible? Merlin, ATA, RD Motor and Grifco—matched to door size/weight/duty.
  • Are wind-rated options available? Yes—wind-strong (cyclonic), wind-locked and semi‑commercial specifications.
  • What about warranties? Written coverage for door, hardware and opener; keep proof and maintenance records.

Your next steps

Ready to turn measurements into a door that fits first time? Australian‑made roller and sectional options in COLORBOND or ZINCALUME, wind‑strong/locked and semi‑commercial specs, DIY guides and free door‑to‑door delivery to most main cities make ordering simple and cost‑effective.

  • Confirm mm measurements (width, height, headroom, side room, backspace) and take photos.
  • Pick door type, colour/finish and wind rating for your location.
  • Choose opener and extras: remotes, keypad, safety beams, smart control.

Start your quote at DoorSupply.