Building an Exterior Door

[pellegrino]

Anyone ever do this before? We'll need to replace both our front and back doors within the next few years. When we replaced our windows we got estimates for doors as well. Because our house is old and has a non standard door size for both, it will cost upwards of $3k for the front door and $2k for the back. It's not an immediate need, and I figure the materials to build it would cost substantially less. I could work on it at my own pace, get hinges the same size and then install would be a piece of cake.

Any thoughts? Has anyone here ever built an exterior door?

[creekster]

Anyone ever do this before? We'll need to replace both our front and back doors within the next few years. When we replaced our windows we got estimates for doors as well. Because our house is old and has a non standard door size for both, it will cost upwards of $3k for the front door and $2k for the back. It's not an immediate need, and I figure the materials to build it would cost substantially less. I could work on it at my own pace, get hinges the same size and then install would be a piece of cake.

Any thoughts? Has anyone here ever built an exterior door?

Depending oj the style it could be pretty diofficult. But you seem to thave the skills to tackle it. Whatr sort of style are you tihnking of? With glass panels?

[pellegrino]

Depending oj the style it could be pretty diofficult. But you seem to thave the skills to tackle it. Whatr sort of style are you tihnking of? With glass panels?

Our neighborhood has restrictive covenants about what we can have. It has to be painted white (cream or any other off white will get you a fine) and it has to be paneled. The original door has four panels and three window panes just below the top rail. There are no side lights. I'd likely build something that is identical or close to what we have already. I'm still in a discovery mode. I think I could do this, but I don't know if I want to commit if it's too difficult or not worth it in the end.

[creekster]

Do you have a planer and an edger/shaper?

[pellegrino]

Do you have a planer and an edger/shaper?

I have a set of good hand planes for edge jointing and if needs be I can hog down panels to a desired thickness with a bit of work. I also have a router and a table. I can purchase pre-made stave cores and then work up a laminate surface for it. I have access to a vacuum press and I might look into what options that presents me.

[wuapinmon]

Having hung an exterior door on my shed in the last 60 days, I can say that it can take a lot longer than you might think (I thought one hour...it took 3). Before beginning, I'd make sure to check the square of the existing door frames. If they're off, you might think of replacing them or adjusting the doors you build to the "off."

[YOUTUBE]ynjOwul-SaE[/YOUTUBE]

Missing from the recommended tools in that video is a big hammer. Sometimes, if the door won't barely fit, if you just knock the ever-loving snot out of the jamb, it'll fix itself.

[FN Phat]

Having hung an exterior door on my shed in the last 60 days, I can say that it can take a lot longer than you might think (I thought one hour...it took 3). Before beginning, I'd make sure to check the square of the existing door frames. If they're off, you might think of replacing them or adjusting the doors you build to the "off."

[YOUTUBE]ynjOwul-SaE[/YOUTUBE]

Missing from the recommended tools in that video is a big hammer. Sometimes, if the door won't barely fit, if you just knock the ever-loving snot out of the jamb, it'll fix itself.

That is great advice...for hanging an existing, pre-hung door. Completely different ball game constructing your own door from scratch. Good luck, Pellegringo. That is a daunting task.

[creekster]

I assumed from your original quesiton that you are only replacing the door and not the frame, right? If so, then you certainly nee dot build it to fit the almost certainly not perfectly square frame, as Wuap suggests. No way around that reality.

If you have a good solid router table and a good router, and you think you can manage without all 10 of your fingers (ok, kidding on the last one) then go ahead and give it a go. Worst case is you waste some money on wood and some fo your time.

If it were me, btw, I would take the old door and the new door to a door shop and pay them to cut the hinge cutouts. They have these cool tools that are very expensive and they can match it up exactly and it is much easier and neater than trying to cut them or chisel them yourself. You will be glad you did this when you try to hang the door in the existing frame. (They can also trim up the top or bottom to match pretty easily too)

[pellegrino]

I assumed from your original quesiton that you are only replacing the door and not the frame, right? If so, then you certainly nee dot build it to fit the almost certainly not perfectly square frame, as Wuap suggests. No way around that reality.

If you have a good solid router table and a good router, and you think you can manage without all 10 of your fingers (ok, kidding on the last one) then go ahead and give it a go. Worst case is you waste some money on wood and some fo your time.

If it were me, btw, I would take the old door and the new door to a door shop and pay them to cut the hinge cutouts. They have these cool tools that are very expensive and they can match it up exactly and it is much easier and neater than trying to cut them or chisel them yourself. You will be glad you did this when you try to hang the door in the existing frame. (They can also trim up the top or bottom to match pretty easily too)

I've installed plenty of pre-hung doors and I've even built a custom frame and hung a door in it. I would be just replacing just the door, not the frame and I know it is somewhat (less than 1/4") out of square. What I had thought about doing was taking precise measurements of the existing door and making it exactly the same dimensions. I might make the glass panes a little larger, but as you said, the exterior measurements would have to be exactly the same to make it work.

Good thought about taking it to a shop, creek. I have a friend who does finish work and has hung quite a few doors. I think I might see if he has a tool he can loan me for a day. IIRC he has an adjustable jig for installing hinges that he uses with his router. That would be handy because once the new door is ready to install, I have to take the old one down, install hinges on the new one and hang it all in one day. Can't give the old door to a shop who will likely want to keep it over night.

I think I might give this a go, probably won't start until next summer, but when I do I'll revisit this thread with pictures.

[creekster]

I've installed plenty of pre-hung doors and I've even built a custom frame and hung a door in it. I would be just replacing just the door, not the frame and I know it is somewhat (less than 1/4") out of square. What I had thought about doing was taking precise measurements of the existing door and making it exactly the same dimensions. I might make the glass panes a little larger, but as you said, the exterior measurements would have to be exactly the same to make it work.

Good thought about taking it to a shop, creek. I have a friend who does finish work and has hung quite a few doors. I think I might see if he has a tool he can loan me for a day. IIRC he has an adjustable jig for installing hinges that he uses with his router. That would be handy because once the new door is ready to install, I have to take the old one down, install hinges on the new one and hang it all in one day. Can't give the old door to a shop who will likely want to keep it over night.

I think I might give this a go, probably won't start until next summer, but when I do I'll revisit this thread with pictures.

The router jig can work too but those usually leave a rounded corner that you still need to chisel out for a square hinge, although that is no big deal. The door shops have a specialized tool I saw them use on an interior door I was installing that was pretty cool.

Either way I look forward to your furhter reports.