How to Fit a Door Into a Non-Standard Frame
Doors and frames are often sold in standard sizes so they can be easily mixed and matched. Because of the precise measurements and preparations required when installing doors and hardware, it can be difficult to find doors that will fit a non-standard frame. To remedy this problem, consider using a door slab for these types of applications. A slab door is generally over-sized and free of hardware preparations so that it can be cut as needed during installation. Does this Spark an idea?
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Things You'll Need
- Tape measure
- Door slab
- Table or circular saw
- Sand paper
- Stain or sealer
- Paint brushes and rags
- 3 hinges
- Hole saw
- Lockset
- Drill
Instructions
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1
Measure the inside dimensions of the frame. Ideally, a door will measure 1/8 inch smaller across the width and at least 1/4 inch shorter than the frame in terms of height.
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2
Purchase a slab door that is at least as large as the opening in the frame. Buy an MDF or hardboard door if you plan to paint, or the wood species of your choice if you plan to stain the door.
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3
Take the frame dimensions you measured in Step 1 and subtract 1/8 inch from the width and 1/4 inch from the height. Mark these dimensions on your slab and use a table or circular saw to cut the slab to the required size. Wear safety goggles and use caution when operating this type of equipment.
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4
Place the door on a pair of padded sawhorses and prepare it for finishing. Sand away any handling marks or rough edges. Use a very fine sandpaper to smooth out the surface, then clean away all dust using a damp cloth or vacuum. Paint or stain the door as desired, including both faces and all four edges. Once the door is dry, apply a clear polyurethane sealer to protect the wood from moisture and humidity damage.
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5
Measure the locations of each hinge on the door frame. You'll need to maintain a 1/8-inch clearance between the top of the door and the frame, so subtract 1/8 inch from each of these dimensions before transferring them to the side of the door. For example, if the top of the first hinge on the frame is 6 inches from the top of the opening, the top of this hinge will be installed at 5 7/8 inches from the top of the door.
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6
Use your tape measure to find the location of the lock strike on the jamb. Measure from the top of the opening to the centerline of the strike, then subtract 1/8 inch before transferring this measurement to the door.
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7
Recess the hinge pockets using a router or chisel. If you plan to use a router, buy a butt hinge template to reduce the risk of errors and make this process much easier. Use a chisel and hammer or mallet to recess the hinges by hand. Once you've created these recesses, screw the hinges to the edge of the door. The surface of each hinge should be flush with the surface of the door's edge.
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8
Open the package containing your lock and remove the paper template. Apply this template to the door so that the centerline of the lock is aligned with the marks you made in Step 6. The centerline of the strike should align with the centerline of the lock, so keep this in mind when applying the template.
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9
Cut holes for the lock on the front and edge of the door in accordance with the template. Use a hole saw or spade bit to make these holes, depending on the diameter. Install the lock into these holes based on the manufacturer's installation instructions.
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10
Install the door in the opening and fasten the hinges to the jamb. Test the door to confirm that it swings freely without hitting the frame and make sure the lock is able to close and latch securely.
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