Installing New Doors

Mark for Hinges and Door Set Place the new door on top of the old door again and mark the hinge locations. Use a combination square to connect the vertical lines for the top and bottom of the hinge. Also mark the knob holes and the backset hole. Use a utility blade to score where the backset face plate and the hinges will go. Score down as deeply as the hinge. Use a chisel to cut a number of lines in the mortised area. Then chisel carefully to remove the waste, one section at a time, keeping the mortise at the proper depth. Place the hinge in the mortise, mark holes for a center punch and carefully drill small pilot holes for the hinge screws. Be sure to check packaging first before setting the holes. Most standard door knob assemblies use a 2 1/8-inch hole saw to cut the door knob hole and a 7/8-inch spade bit to drill out the hole for the backset. Place the backset into the hole and trace around the front plate for the striker, then mortise it in with a utility knife and chisel the same way you did it for the hinge leaf. Install the knob and you're ready to hang the new door.   Checking the door swing tells whether adjustments are needed, especially at floor level where the door is likely to catch on an uneven floor. Enlist your helper again to mount the door putting the top hinge in first and sliding the hinge pin down part way so it holds. Slide the bottom hinges together and put that pin in. Tap them both into place. Pre-hung Doors If you go the pre-hung route, the steps are the same but much simpler. Carefully remove the trim or casing around the door. If you're hanging a new jamb, you'll need to remove all framing parts. The pre-hung door comes with all the hardware and hinges attached. Open the package but do not remove the cross bracing that holds the door jambs in place. Set the complete door in the framed opening and shim the header jamb and side jambs with wooden shims. Make sure that you place shims behind the hinges. Don't force the shims in or you'll bow out the jambs. Slide the shims in gently until they stop.     Finishing Touch If you're planning on painting rather than staining the door, use automotive body filler. Use this two-part product to fill the trim nail or trim screw holes and any other imperfections in the door or jambs. It's quick, easy to work with, sets up fast, and sands beautifully for an extremely fine finish.         Check to make sure the door is square in the frame and check both jamb sides for plumb. Check the top jamb for level. If everything is square in the frame, you can nail the jambs to the frame using finishing nails. Countersink the nails after they're driven in and fill the holes with putty. An alternate method is to attach the door frame with trim screws. The head is a bit larger than a trim nail, but is still easily covered with putty once countersunk. An added benefit is that you can take them out if the door frame shifts during installation. Cut off the excess shim material, and install the trim around the door.

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