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Interior door replacement is cheap but difficult | Home and Garden
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Interior door replacement is cheap but difficult | Home and Garden

Q: My son got angry and kicked the door through. Now I need to replace it. It is a flat, hollow interior door without panels. Instead of installing a more expensive, pre-hung door, I want to remove the door from its hinges and install a new door. How difficult is this?

A: Hollow-core interior doors are inexpensive to replace. But hanging them correctly is a completely different matter.

To start, measure the door and purchase a new one from the home center. The door you purchase will likely be slightly larger than the door you are replacing. Don’t worry about this; you will just need to trim it.

Unless you have some special tools, purchase a door that has pre-drilled holes for the handle and latch.

Remove the doorknob by unscrewing the two screws that secure it to the door. The screws may be visible, but you will most likely need to remove the cover plate on one side of the door handle. Pry it up with a standard screwdriver and remove the screws.

Tap the hinge pins up and out and lift the door. Remove the hinges from the door and set them aside.

At this point you will use the old door as a template to mark and cut the new door. A hollow door has solid wood only around the edges. This gives the hinge screws and doorknob something to bite on. (Hey, there’s an idea for your son!) It also adds some stability to the hollow door.

Lay the new door on the ground and then place the old door on top. Make sure the doorknob holes are aligned and the front edge is smooth. Use a pencil to draw lines on the new door and trace around the old door.

You only need to cut one strip from the back edge of the door. If you cut too much, the hinge screws will have nothing to bite into. If your door is not a standard size, you may need to order a custom door.

The best way to cut the back edge of a door is with a table saw, but a guided circular saw works just as well.

Use a circular saw to cut the height of the door, but make sure you don’t change the position of the door handle hole. For example, if the doorknob hole is 35 inches from the bottom of the old door, make sure it is on the new door as well.

Once the door is cut to the desired size, insert the hinges into the tenon. Mortising in this case refers to cutting the full depth of the hinge to the edge of the door so that the hinge is flush with the door when screwed on.

Hold the old door and the new door aside with the door handle holes aligned and facing down. Mark the locations of the hinges on the back edge of the new door.

The quickest and most accurate way to cut a tenon is to use a router and hinge template. However, if you don’t plan to do a lot of woodwork, forgo the expense of these tools and opt for a hammer and chisel, a faithful replacement.

Take the hinge and outline it in the places you marked. Make sure the hinges are in the same place as the old door. Tap the chisel along the outline to cut the edge of the tenon. Then make shallow passes to remove wood inside the outline. Test the depth of the mortise from time to time by inserting the hinge. If the hinge is not aligned, remove more wood until it is aligned. Repeat the same process for the other hinges.

Once the tenons are all cut, screw the hinges into the tenons. Lift the door up and re-hang it by aligning the hinges and inserting the hinge pins.

Test the swing of the door. If it is sticking along the top or side, use a block plane to level the contact point. You’ll probably have to repair the door to get it right.

Reinstall the handle and latch and make sure it contacts the strike plate. If it does not lock, leave the door alone and move the strike plate. It’s much easier than re-cutting the hinges.

When the door opens the way you want it, paint it and think about taking your son to the football field.

Mike Klimek is a licensed contractor and owner of Las Vegas Handyman. Send your questions to [email protected] or 4710 W. Dewey Drive, No. Send it to 100, Las Vegas, NV 89118. Visit handymanoflasvegas.com.

do it yourself

Project: Install an interior door

Cost: From about $60

Duration: 1-2 hours

Difficulty: ★★★