Step by step
Step A
Carefully remove the old door, making sure the weight of the door is supported when you remove the final screws.
Step B
Stand the new door up in the doorway to check whether it needs trimming. If it does, use a pencil to mark the top of the door opening onto the new door.
Step C
Secure the door to your workbench with clamps. Measure the distance that needs trimming and divide that measurement equally across the top and bottom of the door. Then, add an additional 3mm to both ends to allow for clearance.
Step D
Carefully mark a cutting guideline on the bottom of the door. If you are only removing a small amount of excess wood, trim using a plane. Alternatively, use a panel saw or circular saw to remove larger amounts. Ensure that you cut in a completely straight line.
Step E
Now that the door is cut to height, hold it up against the frame to check whether the width of the door fits. If it doesn’t, hold the door so one side is in position and then mark the overhanging distance onto the door.
Step F
Measure the overhang and divide the measurement equally across both sides. Then add an extra 3mm onto each side to allow for clearance.
Step G
Draw a cutting guideline then remove the excess wood with a plane or saw.
Step H
Put the door into position and place small wedges underneath it to lift it off the ground. Position the door so there is a consistent 3mm gap between the door and the frame on all sides.
Step I
Once the door is in position, use a pencil to mark the position of the existing hinges onto the door.
Step J
Lay the door onto your workbench and align the hinges you will be using with the marks you made. Carefully draw around the hinges to mark their outline onto the door.
Step K
Measure the thickness of the hinge plate then mark a line of the same thickness onto the edge of the door.
Step L
Using a sharp chisel, cut around your pencil lines to clearly mark where the hinges will be situated.
Step M
Then, position the chisel at a 45-degree angle to the door and, using your pencil mark as a guide, make small cuts at 5mm intervals to the same depth as the hinge plate.
Step N
Next, turn the flat side of the chisel towards the door and chisel out the recess for the hinge plate.
Step O
Put the hinges back into position and drill pilot holes. Then, carefully screw the hinge plates to the door using the provided screws.
Step P
Place the door against the frame and position it so that it is open to 90 degrees.
Step Q
Put the first screw through the lowest hole of the top hinge plate and secure it in place.
Step R
Then, put a screw through the lowest hole of the bottom hinge plate and secure.
Step S
Put the third screw into the top hole of the top hinge. Once these three screws are in place, check that the door opens and closes without catching
Step T
Once the door opens / closes cleanly, crack on finishing touches such as painting the door or making cut-outs for handles or latches. Then finally, screw in the remaining screws to secure the door and job done!