Apology in advance. I am going to use mm instead of inches. Can anyone explain the rebate size on the door frame to receive a 40mm thick door. I have noticed that some door frames allow a little extra. Is there a general rule of thumb here or a principle to allow for a door seal around the frame or is it simply to prevent the door binding when closed. cheers
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With a perfectly fit door you could get away with half a mm. But the door would only operate for about an hour before dimensional changes caused it to jam.
The main issue besides simple "breathing room" is that the leading edge of a closing door projects farther than the trailing edge, relative to the hinge point (the old squaw on the hippopotumus thing). And the jambs are generally square to the wall, and not slanted in or out. So either the door edge must be tapered slightly or the jambs must be slightly farther apart, to allow the leading edge to clear the jamb.
But, either way, once the door is closed there is necessarily a gap between door and jamb where the leading door edge meets the stop. The "rebate" must be large enough to cover this gap comfortably.
Additionally, of course, the larger the rebate the better the job the door does at sealing.