The remaining steps to hanging a door are all that’s left.
First, you have to make the
little bugger unwieldy beast fit. This one was very close but about half an inch had to come off the bottom.
There are three hinges and each needs a notched out space on both the edge of the door and the door frame so it will be flush with the surface.
This can be accomplished either by a router or a hammer and chisel. Charlie chose hammer and chisel since most of the notches were already made and only needed to be doctored a bit because this door would open to the outside (most front doors open in).
Next we screwed in the hinges to the door and the frame after making pilot holes with a nail. One caution: if you’re using a screwdriver drill attachment, make pilot holes because the door wood is very hard and just letting the drill screw in the screws often messes up the top of the screw making it nearly impossible to remove that screw. Note above the part of the hinge that goes onto the door. The matching section gets screwed into the door frame.
Then we matched up the male and female edges and dropped (hammered) the pins in. And the door was too big to fit into the opening side to side.
We checked it with a level and discovered the hinges attached to the frame were slightly out of plumb. So Charlie removed the door again and set the top hinge a little deeper into the frame. This is a very precise operation.
Still the door wouldn’t close all the way so we had to make a
few dozens of passes with the Surform both to the door and jamb on the latch side to detail the fit.
Finally the door closed all the way.
Then we gave it a fresh coat of paint both inside and outside, screwed on the door handle and lock set, and replaced the weatherstrip along the bottom edge. Here’s the door we removed.
May I present Morgan* the Cottage Door.
We learned how to hang an exterior door in an existing jamb and saved a ton of moolah over buying a new door. The cost breakdown is:
Door and lock set $35.00
Keys for the door $13.00
Brasso $ 6.00
Hinges and screws -0-
Paint (from our stash) -0-
*Morgan is stamped into the top of the door and the number 73. A similar door retails for approximately $1000. Yikes!!
How did we do?