Abstract: An overhead garage door panel has a thin outer metal skin. Along the upper and lower edges of the outer metal skin are top and bottom flanges. The top flange has a rib formed therein which is adapted to mate with a groove formed in the bottom flange of an adjacent corresponding panel. A foam insertion core fills the pan and flanges of the outer skin thereby providing the requisite strength and rigidity in combination with the flanges. The foam core is formed in-situ and a back skin extending between the flanges retains the foam within the panel during the foaming process. Adjacent panels are hinged together and a reinforcing member is glued within each flange to provide a secure mounting attachment for the hinges.