How to Replace a Door

Replacing a Door Panel in an Existing Door Frame

Introduction:

From time to time a door panel may become damaged and need replacement. Hanging a wooden door in an existing door frame is an easy DIY task but it must be done correctly to avoid uneven gaps in the spaces around the door and insure that the door latches correctly. The following technique is offered on how to replace a door panel in an existing door frame.

Door panel

1. Remove the old door panel by removing the screws in the hinge that attaches it to the door frame and then remove the hinges form the door panel. Save the hinges for reinstalling on the new door.

2. If you are lucky, the replacement door will be the exact same size as the old door, unfortunately this is not always the case. So measure the door frame opening using a standard tape measure.

3. If necessary, trim the replacement door to slightly smaller (¼ inch) than the finished opening to allow a small margin for closing the door.

4. Mark the door for trimming using a pencil. Allow a (1/6 inch) space between the door and the top and each side. The bottom of the door should be (1/4 – 1/2 inch) up from the floor to allow for carpeting or a wood floor.

5. Trim the door to the pencil marks using a power saw and plane as necessary then sand the edges as necessary until they are smooth.

6. Fit check the door by standing it in the door frame. Use shallow wedges underneath the door see if it fits properly. If it doesn't, you will need to make adjustments until the fit is perfectly.

7. Determine which direction you want the door to open. Normally the door should open into the room depending if there is a light switch. If the light switch is on the right as you enter the room then the hinges should be on the left.

8. Place the door on a work table with the hinge side upwards. Mark the location of the hinges by drawing around the hinge.

9. Cut the hinge mortises using a chisel to make shallow mortises within the pencil marks. Remove the surplus wood and trim the recess until the hinge is flush with the edge of the door wood. Be careful to not chisel out too much material.

10.Drill pilot holes to attach the hinges and attach the hinges to the door panel.

11.Mark the hinge positions on the door frame. Use wedges at the bottom of the doorway to hold it in the correct position. Draw around the hinges with a pencil then set the door aside.

12.Chisel the hinge mortises. Position the door in the the frame again to check the hinge location.

13.Drill pilot holes on the frame hinge location and install the screws securing the door to the frame.

14.Make minor adjustment as necessary.

That is how to replace a door in an existing door frame.

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