Better Homes and Gardens (Australia)
EASY STEPS TO REPLACE YOUR FRONT DOOR
Gather your supplies
• Exterior door slightly larger than existing
• Hinges to match dimensions of existing
• Door handle, locks or deadbolt
You’ll also need
Spirit level; screwdriver; circular saw; planer; combination square; pencil; scrap plywood; drill; knife; hammer; chisel; sander; paint or clear exterior varnish; painting equipment; 54mm hole saw; 25mm spade bit
Here’s how
STEP 1 Survey the old door to see if it closes properly with minimal gaps. If you can make the new door a be er fit, with a 2mm gap to top and sides, now is your chance. Note on the old door how much bigger the new door needs to be. Also use a spirit level to check the hinge side of the door jamb for plumb. If it isn’t, you will have to replicate this on the new door (see Step 3).
STEP 2 Use a screwdriver to undo screws from the old door and remove. Also take hinges and handle or deadbolt off the old door.
STEP 3 Sit the old door on top of the new and align the hinged edge of the old with the edge of the new. Also make sure the old door sits entirely on the new and is not hanging off the edges. If you identified that the hinge side of the door jamb is out of plumb in Step 1, adjust position of old door on this edge to reflect this so top and bo om of new door will be level. Trace along this edge, then cut or plane it before proceeding.
STEP 4 Use a combination square to mark position of old hinges on the edge of the new door. Mark the interior side of the new door so that when you cut the housing for the hinges, it is facing the right way.
STEP 5 Trace around the outside of the old door on the new. Take into account the notes you made in Step 1 so the door is a be er fit in the jamb. Cut or plane the new door along the traced lines. Be careful you don’t cut off too much. You can always cut off more but you can’t add it back on.
STEP 6 Use scrap ply to make a door clamp to hold door upright with hinged edge facing up. Tap clamp in place to secure the door.
STEP 7 Screw hinges on new door in areas marked from the old. Use a sharp knife to scribe around the hinge to cut timber, then remove hinge.
STEP 8 Use a hammer and sharp chisel to go around the line cut by the knife to make it deeper. Hold the chisel so the bevelled edge on the end is facing the inside of the housing.
STEP 9 Use chisel to make a number of cuts across the housing to make it easier to remove the timber.
STEP 10 Use the chisel to cut the housing to a depth that matches thickness of the leaf of the hinge. Hold
chisel with the bevel cu ing edge down. This makes the chisel cut in an upwards direction, ensuring you don’t cut too deep. To make bo om of housing smooth, turn the chisel over, hold it flat and shave off the excess timber. Check the fit of the hinge as you work so you don’t shave off too much.
STEP 11 Screw new hinges into housings on the door.
STEP 12 Bring door near the jamb in open position. Sit door on a wedge to raise it up until hinges go in old housings in jamb. Screw hinges to jamb. Use only 2 screws per hinge, then check fit of door in jamb, looking at hinge side first. If the door binds on this side, use thin pieces of cardboard behind hinges to increase gap between door and jamb. If gap is too great, shave more timber out of the housings to close gap.
STEP 13 Once happy with hinge side of door, check fit against other edges. If the door fits within the jamb but the gaps are uneven, pack behind the hinges until they are. If the door doesn’t fit, hold it closed against jamb and mark on the outside of the door the line of the jamb. Remove door and plane or sand until it fits with an even gap all around. Take time to remove and rehang door as needed to check the fit so you don’t take off too much.
STEP 14 Sand cut edges of door to remove the cu ing marks and make smooth. Paint or coat the top and bo om of door to seal them and prevent water entry. STEP 15 Hang door in opening, pu ing all screws in hinges.
STEP 16 Use template that comes with door furniture to mark drill points on door.
Use tool recommended by manufacturer for main part of the lock or handle, here a 54mm hole saw.
STEP 17 Drill hole through edge of door for barrel of handle, using a 25mm spade bit. Make sure you find the centre of the door to use as the centre of your hole.
STEP 18 Insert latch into door and temporarily screw in place. Cut around edges of latch using a sharp knife, then use chisel to house edge of door for latch plate. STEP 19 Paint or coat door before you a ach the door furniture. Let dry and sand lightly between coats. If painting a glazed door, leave protective plastic on glass until finished painting. STEP 20 A ach latch, locks handles or any other door furniture you have. for PROJECT SUPPLIES, see OUR stockists page