A single dented, cracked, or rusted garage door panel doesn’t mean you need a brand-new door. Many homeowners don’t realize that replacing just one or two damaged panels costs a fraction of full door replacement and restores both function and curb appeal instantly.
At Trusty Garage Door Repair, we help Plano homeowners save thousands by identifying when panel replacement makes sense versus when full replacement is necessary. This guide covers everything about garage door panel replacement: panel types, exact costs, how to identify compatible panels, and why professional installation matters for safety.
Panel Replacement vs. Full Door Replacement: Quick Decision Guide
Confused about whether to replace one panel or the whole door? Use this quick reference:
| Situation | Best Solution | Estimated Cost |
|---|---|---|
| Single panel dent or crack | Panel replacement | $250–$800 |
| 2–3 damaged panels | Evaluate structural integrity | $500–$1,500 |
| 4+ damaged panels or frame damage | Full door replacement | $1,200–$2,500+ |
| Door older than 15 years | Full replacement recommended | $1,200–$2,500+ |
| Material/design discontinued | Full replacement only option | $1,200–$2,500+ |
| Minor cosmetic issue on newer door | Panel replacement | $250–$800 |
| Structural issues (sagging, misalignment) | Professional inspection required | Varies |
Table of Contents
Pro tip: Even if one panel is damaged, always get a professional inspection. Sometimes what looks like panel damage is actually a frame, track, or spring issue that requires full replacement.
Garage Door Panel Types & Replacement Costs
Not all garage door panels are alike. Understanding your door type is essential for accurate pricing and compatibility.
Sectional Door Panels (Most Common – 85% of homes)
Sectional doors have 4–8 horizontal panels that slide up and down on tracks. Individual panels are highly replaceable.
Steel sectional panels:
- Cost: $150–$400 per panel + $100–$200 labor
- Total with installation: $250–$600 per panel
- Best for: Budget-conscious homeowners; extremely durable
- Maintenance: Minimal; repaint every 5–7 years
- Compatibility note: Steel panels are standardized; easy to source matches
Insulated steel sectional panels:
- Cost: $250–$500 per panel + $150–$250 labor
- Total with installation: $400–$750 per panel
- Best for: Cold climates; energy efficiency; noise reduction
- Insulation value: Reduces heat loss by 10–15%; good investment long-term
- Note: Thicker panels require careful alignment during installation
Aluminum sectional panels:
- Cost: $200–$450 per panel + $100–$200 labor
- Total with installation: $300–$650 per panel
- Best for: Homes in coastal/salty areas; rust prevention
- Advantage: Lightweight; easier to handle during replacement
- Trade-off: Less durable than steel; dents more easily
Wood or composite sectional panels:
- Cost: $300–$800+ per panel + $150–$300 labor
- Total with installation: $450–$1,100+ per panel
- Best for: Premium aesthetics; carriage-house or farmhouse styles
- Maintenance: Requires staining/sealing every 2–3 years
- Why expensive: Custom sizing common; requires precise finishing
Insulated or custom sectional panels:
- Cost: $400–$1,000+ per panel
- Total with installation: $600–$1,300+
- Used for: High-end homes; specialized thermal requirements
- Lead time: 2–4 weeks for availability
Tilt-Up/Swing-Out Door Panels
Older homes sometimes have single-panel tilt-up doors. These are one large panel that swings upward.
- Cost to replace entire tilt-up panel: $600–$1,500 + $200–$400 labor
- Challenge: Limited panel availability; often custom-sized
- Installation difficulty: Higher complexity due to heavy weight and spring tension
Roll-Up/Coil Doors
Commercial-style rolling doors use individual slats rather than panel sections.
- Cost per slat: $50–$150
- Labor for slat replacement: $100–$200
- Total for multiple slats: $200–$600
- Best for: Commercial buildings; industrial looks
How to Identify Your Garage Door Panel Type
Before getting a quote, identify your door:
Check if your door is sectional:
- Look at the door from the side
- Do you see horizontal lines/seams dividing the door into rectangular sections? → Sectional
- Is the entire door one smooth panel that tilts up? → Tilt-up
- Does the door roll up like a coil? → Roll-up
Find your brand and model:
- Check the garage door opener motor (wall-mounted unit)
- Look for a model sticker/plate on the door frame
- Note the size (16’×7′ is standard for 2-car; 9’×7′ for single)
Measure your panel:
- Standard panel width: 42–48 inches
- Standard panel height: 15–18 inches (sectional doors typically 4–5 panels tall)
- Custom panels vary; write down exact measurements
Take photos:
- Damage location (top, middle, bottom)
- Panel color and finish (matte, gloss, woodgrain)
- Any visible brand markings or model numbers
Why this matters: Panels are NOT universal. A Wayne-Dalton panel won’t fit a Clopay door. Matching size, thickness, and design is critical.
Cost to Replace Garage Door Panels: Detailed Breakdown
Here’s what you’ll actually pay for a professional panel replacement:
Single Steel Panel Replacement (most common)
- Panel (standard size): $150–$300
- Hardware (hinges, brackets, fasteners if needed): $30–$60
- Labor (1–1.5 hours): $100–$200
- Travel/service call fee: $0–$50 (varies by company)
- Total: $280–$610 per panel
Two Panel Replacement
- Two panels: $300–$600
- Hardware: $50–$100
- Labor (2–2.5 hours): $200–$350
- Total: $550–$1,050
Insulated Panel Replacement
- Panel: $250–$500
- Additional hardware (thicker hinges required): $50–$100
- Labor (1.5–2 hours due to extra weight): $150–$250
- Total: $450–$850 per panel
Premium/Wood Panel Replacement
- Panel: $300–$800+
- Finishing/staining if color match needed: $100–$300
- Labor (2–3 hours): $200–$350
- Total: $600–$1,450 per panel
Why Single Panel Replacement Sometimes Backfires: Important Warnings
Before you replace just one panel, understand these potential issues:
1. Color/Finish Mismatch
- New panels may not exactly match 10-year-old painted panels
- Weathering, UV exposure, and paint fade cause visible differences
- Solution: Paint entire door ($200–$400) or accept slight mismatch
2. Hidden Damage Discovery
- What looks like panel damage might be bent tracks or frame issues
- Once panel is removed, you may discover structural problems
- This can convert a $400 repair into a $1,500+ project
- Always get a pre-inspection
3. Misalignment Issues
- Forcing a new panel onto misaligned tracks damages the panel
- Doors that sag on one side indicate frame or spring problems first
- Panel replacement alone won’t fix underlying mechanical issues
4. Spring and Hinge Wear
- Garage door springs last 10,000–15,000 cycles (~10 years)
- If your door is 12+ years old, springs may fail soon after panel replacement
- Budget for potential spring replacement ($200–$400) in aged doors
5. Discontinued Panels
- Doors older than 15 years may have panels no longer manufactured
- Some budget brands don’t keep inventory
- You may be forced into full door replacement anyway
- Check availability BEFORE committing to panel-only repair
When to Replace One Panel vs. When to Replace the Entire Door
Replace just the panel(s) if:
- Door is less than 15 years old
- Damage is isolated to 1–2 panels only
- Rest of door operates smoothly with no sagging, sticking, or noise
- Panel model/size is still available from the manufacturer
- Door has had regular maintenance (well-functioning springs, tracks, hardware)
- You’re fine with potential minor color variation
Replace the entire door if:
- Door is older than 15 years (parts availability drops)
- Multiple panels (3+) are damaged
- Panels are discontinued or difficult to source
- Frame is bent, sagging, or misaligned
- Springs are broken or showing rust
- Door moves slowly, jerks, or sticks regularly
- You want better insulation/energy efficiency
- Home improvement/resale value matters
Get a professional inspection if:
- You’re unsure about damage severity
- Door has repeated problems despite repairs
- You want a definitive recommendation before spending money
How Professional Panel Replacement Works
Understanding the process helps you see why professional installation is safer and better:
Step 1: Damage Assessment
- Technician inspects not just the panel, but the entire door system
- Checks for track misalignment, spring tension, hardware wear
- Identifies whether panel-only replacement will solve the problem
- Takes measurements and notes color/finish details
Step 2: Source Matching Panel
- Researches your door model and manufacturer
- Orders exact-match panel (size, material, insulation, color)
- Confirms availability to avoid delays
- Typical turnaround: 3–7 days; rush available for extra cost
Step 3: Tension Release (Critical Safety Step)
- Technician releases spring tension before touching the door
- Manually deactivates openers
- This prevents the 400+ pounds of stored energy from causing injury
- DIY failure here = trip to emergency room
Step 4: Panel Removal
- Disconnects and carefully removes damaged panel
- Cleans track area and inspects for debris or damage
- Reuses existing hinges, hardware, and brackets if in good condition
- Disposes of old panel responsibly
Step 5: New Panel Installation
- Aligns new panel perfectly with tracks
- Reconnects all hinges and brackets to manufacturer specs
- Verifies smooth operation in tracks before finalizing
- Tightens all fasteners and checks for wobbling
Step 6: System Testing
- Tests door movement through complete up-down cycle
- Verifies auto-reverse safety sensors function
- Checks that opener engages smoothly
- Confirms balance and alignment
Step 7: Cleanup & Warranty
- Cleans work area
- Provides warranty documentation (typically 1–5 years on labor)
- Shows you basic maintenance tips for longevity
Can You Replace a Single Garage Door Panel Yourself?
Short answer: Don’t do it.
Why professional installation is essential:
- Extreme spring tension – Garage door springs store 400+ pounds of force. Accidental release causes severe injury or death.
- Precise alignment required – Panels must sit perfectly in tracks. Misalignment damages new panels and strains the door system.
- Safety sensor calibration – Auto-reverse sensors must be properly positioned. Incorrect installation = safety hazard.
- Warranty voided – DIY installation voids manufacturer warranties on both door and opener.
- Tool requirements – Spring tensioners, panel lifts, and specialized tools aren’t worth buying for one-time use.
- Hidden problems – Without expertise, you may not recognize track damage, spring wear, or structural issues that turn a panel job into a full replacement.
- Liability – If something goes wrong, you’re liable for injuries or property damage.
Cost comparison:
- Professional panel replacement: $250–$800
- Emergency room visit for spring-related injury: $5,000–$50,000+
The math is simple: hire a professional.
Matching Your Old Panel: Color, Finish & Material Guide
Getting a perfect match matters for curb appeal. Here’s how professionals match panels:
Material Matching (Most Important)
- Bring old panel photo to supplier or provide exact model number
- Steel, aluminum, wood, and composite require different suppliers
- Thickness must match (usually 24–27 gauge for steel)
Color Matching Options
- Exact brand match: Order through same manufacturer (best option)
- Touch-up paint: Acceptable if one panel is being replaced
- Full-door repaint: $200–$400, guarantees uniformity across all panels
- Live with slight variation: Minor weathering differences often go unnoticed
Finish Options
- Matte (flat finish): Most common; hides minor scratches
- Gloss: Shinier appearance; shows dust/fingerprints more
- Woodgrain or textured: Premium appearance; pricier panels
Pro Tip: If your door was painted custom colors years ago, full-door repainting is often cheaper than trying to match that old paint. Modern paint technology offers better durability anyway.
Garage Door Panel Maintenance: Extend Your Panel Life
Replacing panels now? Here’s how to prevent future damage:
- Annual inspection: Look for dents, rust, or warping before they worsen
- Clean regularly: Remove dirt and salt buildup (coastal areas especially)
- Repaint every 5–7 years: Protects against rust and UV damage
- Check weatherstripping: Damaged seals let water in, causing rust from inside
- Align tracks: Misaligned tracks stress panels; get adjusted annually
- Maintain springs: Replace at 10-year mark proactively; worn springs stress panels
- Avoid impact: Keep items away from door; train kids not to hit it
Frequently Asked Questions About Panel Replacement
Can I replace just one garage door panel? Yes, if it’s a sectional door, the panel matches your model, and the rest of the door is in good condition. Tilt-up doors are more complex; sometimes full replacement is necessary.
What’s the cost to replace a garage door panel? Typically $250–$800 total (panel + labor). Steel panels are cheapest ($250–$600); wood/composite run $450–$1,100+.
Are garage door panels universal? No. Each brand (Wayne-Dalton, Clopay, Amarr) and model has specific panel dimensions, thickness, and attachment methods. Mixing brands doesn’t work.
How long does panel replacement take? Professional installation typically takes 1–2 hours for a single panel; 2–3 hours for two panels.
Should I replace one panel or the entire door? If the door is under 15 years old, only one panel is damaged, and parts are available—panel replacement saves money. If the door is old, damaged on multiple panels, or difficult to match, full replacement is often wiser long-term.
What if I can’t find a matching panel? If panels are discontinued, you have three options: paint the entire door to hide mismatches, explore aftermarket/compatible panels, or replace the full door.
Will my warranty cover panel replacement? Most manufacturers offer 10-year warranties on doors but exclude DIY damage. Professional installation warranties typically cover the panel and labor for 1–5 years depending on the company.
Need Expert Panel Replacement Guidance?
Not sure if one panel or a full door replacement is right for you? Trusty Garage Door Repair offers free in-home inspections in the Plano, TX area.
We’ll:
- Assess panel damage and overall door condition
- Check parts availability and exact pricing
- Explain your options (panel replacement vs. full door)
- Provide a transparent, written quote with zero surprises
- Handle professional installation with a warranty
📞 Call 214-624-6348 or Book Online to schedule your free inspection today.