How to Install an Interior Door Slab

When installing a new door into an existing frame, it is often difficult to find a door with the right measurements to fit the frame. While doors can be cut down to fit, they often have pre-drilled lock and hinge preps that will not align with those on the frame. To remedy this problem, many installers will use a door slab for this type of application. A slab does not have any hardware preparations, and can be easily cut to any size depending on the layout and configuration of the frame.

Things You'll Need

• Door slab
• Hammer
• Center punch
• Tape measure
• Circular or table saw
• Pencil
• Hole saw
• Drill
• Utility knife
• Chisel or router
• Hinges
• Lockset

Instructions

1. Remove the existing door from the hinges. Line a center punch up with the hinge pin, then use a hammer to drive the pins out. Once all the pins are out, remove the door from the opening and set it aside for disposal. If the door is in good condition, consider donating it to a local construction salvage facility.

2. Measure the existing door, including the thickness. Choose a new door slab that's roughly the same size as your existing unit. It should be exactly the same thickness, but can be slightly larger in height and width.

3. Cut the new door so that it is the same height and width as your old door. Use a circular or table saw to make these cuts.

4. Use a tape measure to determine the locations of the hinges and lock on your old door. Transfer these measurements to your door slab, marking the perimeter of each hinge as well as the centerline of the lockset.

5. Drill a hole in the slab for the lock. Use a hole saw to create a 2-1/8" hole (or one that fits your lock) on the face of the door as well as a 1" hole on the edge of the door for the latch. These holes should be located in exactly the same spot as they were on the old door. The sizes listed are standard for cylindrical locksets. If yours is not standard, create holes that are correctly sized for your lock.

6. Insert the locking mechanism into the edge of your door. Scribe around the latch plate on the edge of the door using a utility knife. Remove the latch and use your chisel or router to create a recess in the edge of the door for the plate. The recess should be as deep as the height of the latch plate.

7. Create recesses for the hinges using your router or chisel. When using a router, it is helpful to use a simple butt hinge template to guide the router. Many installers still prefer chiseling out hinge pockets by hand with a hammer and chisel, however.

8. Screw the hinges into place on the edge of the door. If you plan to reuse the old hinges, you'll only need to install the leaf that goes on the door. The remaining leaf should still be fastened to the frame.

9. Pre-drill screw holes as needed for the lock. Insert the latch into the edge of the door, then install the trim by lining up the connecting rods on each side. Use set screws to fasten the lock to the door.

10. Hang the door on the hinges by hammering the hinge pins back in. Test the door to make sure the lock works with the existing strike.

References

• Kent Home Improvement
• Curtis Lumber
• Homestead Interior Doors