Slab doors are available in many different finishes to match any decor.
A slab door is a blank door that does not contain preps or cut-outs for hinges, locks and other hardware. When you install a new door in an existing frame, a slab is often the best choice, as it allows you to prep the door as needed to fit the frame. While this process is slightly more difficult than hanging a pre-hung unit, it provides a much greater degree of flexibility and customization. Take the time to make precise measurements and prepare your door carefully to ensure it will function as intended.
Instructions
Cut the Door to Size
1. Measure the inside opening of your frame. The height should be measured from the floor to the underside of the frame header, while the width is measured from the inside face of one jamb to the inside face of the other.
2. Buy your door slab. Choose a slab that is at least as big as the inside of the frame opening.
3. Cut the door to fit the opening using a hand or circular saw. The door must be undersized slightly to provide clearance within the frame. Cut the door so that it is 1/4 inch narrower than the frame and 3/4 inch shorter than the frame. For example, a frame measuring 3 feet wide by 7 feet tall requires a door measuring 35 and 3/4 inches wide and 83 and 1/4 inches tall.
Install the Hinges
4. Measure the location of each hinge along the edge of the frame. Determine the distance from the top of the frame to the top of each hinge. Before transferring these measurements to the door, subtract 1/8 inch from each distance. This 1/8 inch provides clearance space at the top of the opening so the door will not bind with the frame. For example, a hinge that is 6 inches from the top of the frame should be installed 5 and 7/8 inches from the top of the door.
5. Select a hinge template that matches your hinges in both size and profile. Standard hinges measure 4 inches tall, though others may be 4 and 1/2 inches or even 5 inches. Check to see if your hinges have square or rounded corners and make sure the template matches.
6. Place the template onto the edge of the door so it lines up with the top hinge location. Use small finish nails to hold the template in place as you work.
7. Install a guide bushing onto your router, then set the height of the router to the thickness of the hinge (typically 1/8 inch). Insert the router inside the template and switch it on. Move the router around inside the template until you have created a pocket for the hinge. Remove the template and repeat this process to create cut-outs for the remaining hinges.
8. Screw the hinges to the door using the fasteners provided.
Install the Lock
9. Measure the height of the strike on the frame. Take this measurement from the floor to the centerline of the strike. Subtract 1/8 inch before transferring this measurement to your door. This 1/8 inch provides clearance at the top of the door to ensure smooth operation.
10. Use the lock template and instructions that came with your lock to install the lock on the door. Use a circular saw to create holes for the lock and bolt, then recess the latch plate in the edge of the door using a hammer and chisel.
11. Have a partner hold the door in the opening as you attach the hinges to the frame. Use the screws provided for this task, and fill all pre-drilled holes in the hinge leafs with screws. Close the door and test its operation to complete the project.
Related posts
Exterior doors need to be secure.Exterior doors take a lot of punishment during their lifetime having to cope with different weather conditions all year round. Both doors and frames can be suscept...
Interior doors are often important focal points of any room in a home. Like any door that sustains use, an interior door can chip, crack and collect dents and scratches over time, in addition to l...
Remove chipped paintwork and prepare the door thoroughly before applying primer and paint.You may not notice the chipped paintwork on one of the doors in your home. However, you can bet it will be...
Colored doors add visual interest.Paint your doors if you're redecorating, or if you just want to breathe new life into a living area. Like other home painting projects, painting doors involves so...
Properly painted door trim can last for years.Exterior wood trim on doors needs to be prepared properly before painting. Bare wood is porous, and finish paint soaks in. This soaking-in process can...
