Not talking anything special, fancy or unique here. Trying to replace the exterior entry door of a small 4-flat building in the Chgo ‘burbs. It’s original, 1950’s construction, heavy as all get out, wood, window about 2/3 the way up. Framed into the brick building. 3-hinge currently, top hinge shows some previous attempts to fix or put in larger screws. Currently, door opens, but sags a bit and therefore won’t completely close. Trouble is… looks like over the years someone tried larger screws, etc… normally I’d consider drilling out screw holes at top, plugging with dowels and re-drilling… but it appears some damage to the door has occurred at some time. Maybe someone drove screws in at a poor angle and it looks like the wood is splitting and cracked at this top hinge location. Any ideas on a fix?? The door isn’t it terrible shape except for this… replacement seems horribly expensive since the door itself (not the frame) is 39″wide… I’d like NOT to reduce this to 36″, tenants moving furniture in & out seems to do less damage with the 39″ width. Any fix ideas or source of a not soo expensive replacement?
THX
Replies
Without seeing the damage it is a little difficult to give advice, but here goes anyhow. What you do is carve out the damaged wood and replace it with solid wood that will hold the screws. I'd probably try to retain the two faces of the stile, so the appearance doesn't change. On the hinge edge of the door, use a plunge router to make a mortise. Then you cut a filler block and glue it into the mortise. The screws will go into the new wood. The glue between the walls of the mortise and the faces of the filler block hold it in position, and help hold the stile together. I'd use a waterproof glue like urea-formaldehyde or epoxy.
This is based on the info you give.
I would remove the door and hinges.
Places where too mauch damage has occoured to the wood jamb can be fixed by using inserts instead of screws. These are wingdings that you install by overdrilling and screwing them in, possibly with a touch of epoxy to hold set. The inner diameter of these is tapped for machine screws that take the place of wood screws. Of course, there is no room for error. There needs to be good alignment with the hinge holes.
The door can be fixed with epoxy. stand it up on the knpb side so the hinge side is up. Drill holes about an eighth inch or 3/16" in around the damaged area. Mask off the area. Mix up your epoxy with fine sawdust and inject or work it in to the holes and maybe some without filler dust into the crack. Sand it smooth when it is kicked hard.
Then re-hang the door.
Excellence is its own reward!
Oh Yeah! Wear some latex or vinyl surgical gloves when you are working this stuff.
Here's a phunny.
The other day I was installing wood screen doors and I read my index wrong when it came to installing the latches. My holes for the bolt were 7/8" but they were supposed to be 5/8". "Oops" I said using my favorite four letter word.
So I dug out a 7/8" dowel and some epoxy. I normally use West System Epoxy but I had some old five minute stuff that needed to get used up.
Of course, the five minute has never set up that fast so I knew I had plenty of time. It was on the second door that I found out I was wrong. I had my glove covered finger in the hole smearing the goop when it happened. If not for the glove, I might have worn the door to bed that night.
Excellence is its own reward!
If you can remove the interior hinge side casing fairly easily, try using T- nuts and flat head bolts to hold the hinges on. Once that works, follow Piffin's instructions for the lockside.
The insert zerts are stronger holding and you don't need to remove the casing or jamb.
Excellence is its own reward!
Piffin -- I'm familiar with the inserts you describe -just didn't trust 'em. Next time I run into a similar situation, I'll give them a try. Thanks. I guess you're never to old to try something new.
Then, just before you hang the door, following all the good advice given before, I would , install one more hinge, probaly , two thirds up between middle and top hinge. I tell you, these boards do me good. Be carefull handling that door. Jim J