Flush garage door panels and method of construction thereof

A flush garage door panel comprising:

• a flush roll-formed steel sheet having a thickness of 0.016 to 0.028 inches, the flush roll-formed steel sheet comprising:
• a flat body;
• an elongated flange extending perpendicularly and rearwardly from a top section of the flat body;
• and
• an elongated channel extending perpendicularly and rearwardly from a bottom section of the flat body;
• a fluted polypropylene plastic sheet having a thickness of 3 to 4 millimeters;
• polyurethane moisture cure adhesive for laminating the fluted polypropylene plastic sheet to a flat inner surface of the flush roll-formed steel sheet;
• two end stiles glued to two opposing side edges of the flush roll-formed steel sheet and metal clinched to the elongated flange and the elongated channel of the flush roll-formed steel sheet;
• and
• at least one center stile glued to an inner surface of the fluted polypropylene plastic sheet and metal clinched to the elongated flange and the elongated channel of the flush roll-formed steel sheet.

A method of constructing a flush garage door panel comprising the steps of:

• creating a flush roll-formed steel sheet by:
• providing a flush steel sheet;
• roll-forming an elongated flange that extends perpendicularly and rearwardly from a top section of the flush steel sheet;
• and
• roll-forming an elongated channel that extends perpendicularly and rearwardly from a bottom section of the flush steel sheet;
• providing a fluted polypropylene plastic sheet with a thickness of 3 to 4 millimeters;
• laminating the fluted polypropylene plastic sheet to a flat inner surface of the flush roll-formed steel sheet with polyurethane moisture cure adhesive;
• pressing the flush roll-formed steel sheet and fluted polypropylene plastic sheet together to remove any waves;
• glueing a first end stile to one side edge of the flush roll-formed steel sheet and metal clinching the first end stile to the elongated flange and the elongated channel of the flush roll-formed steel sheet;
• and
• glueing at least one center stile to an inner surface of the fluted polypropylene plastic sheet and metal clinching the at least one center stile to the elongated flange and the elongated channel of the flush roll-formed steel sheet;
• and
• glueing a second end stile to an opposing side edge of the flush roll-formed steel sheet and metal clinching the second end stile to the elongated flange and the elongated channel of the flush roll-formed steel sheet.