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As noted above, set-screw clamping may have distorted the cross-section of the shaft and made it difficult to slide off all the hardware. With the shaft on the floor, it may be possible to restore enough roundness to proceed, using compensating clamping force to the distorted area via a machinist's vise, an arbor press, a hydraulic shop press, etc., on the shaft body. Burrs and other slight distortions on the shaft can be filed off with a hand file or touched with an abrasive wheel on an angle grinder. At some point, the condition of the shaft may just be degraded enough that it ought to be replaced.
To estimate the maximum physical force required to wind these springs, consider that they are balancing the weight of the door with a torque applied to a lift drum on each end of the torsion shaft. The lift drums have a 2-inch radius, which is the standard residential size, and corresponds conveniently to about a 1-foot circumference. If we pessimistically assume the 10-by-7-foot door has a weight of 350 pounds, this implies a torque of 350 pounds on a 2-inch radius, that is, 700 inch-pounds, or 58 foot-pounds. Each of the two springs should be exerting slightly less than half of the balancing torque, or 29 foot-pounds. Compare this to, say, the bolts in an automobile, which are typically torqued to values of about 50 foot-pounds, or tire lug nuts, which may be torqued to well over 100 foot-pounds.
Spring index lower limit: DASMA standard 102-2004 provides a lower limit of 6 for the spring index, which is symbol C in our formulas above (section 9.3). Other interesting items in this standard include an upper limit for how much the door sags when raised (no more than 1/120 of its width, section 9.2.1), that each of the two bottom brackets should sustain twice the door assembly's weight (section 9.2.2) for a total safety factor of about 4, and that the lift cables should provide a safety factor of 5.
Install the vertical roller tracks first by wrapping the curved lip around the rollers. The top of these tracks should be approximately 8 in. below the top of the top section. Wait to install the upper tracks until this step is complete. Check the level of the top section to make sure the tops of the vertical roller tracks are level with each other. The bottom of the roller tracks should be at least 1/8 in. off the concrete floor. After leveling and mounting these tracks, install the upper roller (horizontal) tracks.
Spring rate and torque: In my spring replacement above, the wire size was d = 0.2253 inches, and the ID was 2 inches, giving a mean diameter D = 2.2253 inches. The number of coils is L/d = 24 inches / 0.2253 = 107, less about 5 dead coils on the winding cones, or 102 active coils. Thus the spring rate is K = (π*28.5*10^6 * (0.2253)^4) / (32 * 102 * 2.2253) = 31.8 in-lb/turn (IPPT). Winding 7.5 turns * 31.8 in-lb/turn yields a torque of 238 in-lbs per spring.
End treatments: Torsion springs also are made in a variety of end treatments. The "standard torsion end" is most common, as is pictured in my examples, consisting simply of a short, straight length of wire projecting tangentially. Various non-standard end treatments have longer "ears", U-turns, ends bent in toward the center or along the axis, or even loops. Non-standard ends are used in end fasteners peculiar to various manufacturers, which would seem to serve mostly as a guarantee that you buy overpriced replacements from that one source.
In each of our branches, we have the best team of expert professionals who know how to handle each and every type of garage door and its components. This is because all of our technicians go through a rigorous training process, covering every known garage door repair technique. We do not let them onto the field until we know that they are completely trained, and can perform a job to perfection. Aside from this, they are continually updated with all the latest knowledge, information and training in order to do their work efficiently.
I backed into my garage door, then my husband tried his hand at fixing it...which only made it worse. The door wouldn't go down and we were leaving town the next day. I called at 9 am on a aturday morning, and Tom called to say he'd be there between 9:45 and 10! He got there just before 10 am and fixed the door in less than 30 minutes. He was very fast, efficient, and knowledgeable. The price was lots lower than I thought it would be. All in all, we were very pleased with the service.
You might genuinely need some extra parts when you thought you simply needed a broken spring replaced, and a good serviceman will perform a simple inspection to identify such parts. Nor is it unreasonable for a business to charge separately for a service call versus repair work actually performed. But the best protection for you as a buyer, being somewhat at the mercy of whomever you decide to bring on site, is to understand what is being done, and ask intelligently for a clear explanation or demonstration of why extra parts are required.