Door Installation Manual

Prior to starting the installation of a new iron front door, you must remove your existing door. That is the first step, and perhaps the most important. You must follow precise steps and be careful not to damage any parts of the existing door, as you may need to use some for the new door. DOUBLE CHECK YOUR MEASUREMENTS TO MAKE SURE THE NEW DOOR WILL FIT PRIOR TO REMOVING YOUR OLD DOOR.

Door Panels

  1. DOUBLE CHECK MEASUREMENTS.
  2. Remove any accessories and hardware that are attached to your existing door. This includes blinds, shutters, and decorative items.
  3. Use a small screwdriver or punch with a hammer to remove the hinge pins. Be sure you have help to stabilize the door as the hinges are being removed.

Remove Casing, Trim, & Jamb

  1. Use a utility knife to cut along the caulk on all sides of the trim. This will make it easier to remove the interior door trim without damaging it.
  2. Once you have all the caulking cut, pry the casing trim away from the wall and the jamb using a small pry tool. Set aside, as you may want to reuse this trim material. 
  3. Use an electric drill to remove the hinges and screws from the old doorjamb. You cannot remove the doorjamb until you have removed these screws. 
  4. You can now start working on the removal of the old threshold and doorjamb. Remove the threshold first, getting it out of the way to make it easier to remove the doorjamb. A pry bar works best to remove the threshold.
  5. You can then use the pry bar to separate the doorjamb from the house. Do not worry if it becomes damaged, as you will not be using it again in most cases. 
  6. You do want to be careful not to damage the exterior brick mold, as this can be reused. Gently pry the doorjamb away from the brick mold, but you do not have to necessarily remove the brick mold. 
  7. Gently pull the pieces of the doorjamb away. If you have wiring for an alarm, be careful not to damage when pulling the doorjamb away.  If you do have an alarm, you may need a technician to assist in this step.
  8. In order to properly install the new door, you will want to clean up any loose materials that are in the doorjamb. Use a shop vac or sweep away dirt, dust, and bits of old door material. Make sure that you scrape all the caulking material off the concrete and remove any nails that are sticking up.

Install New Iron Door

Although installing an iron door is slightly different from a regular door installation, if you have done this before, this should be fairly easy. You will need to be able to plumb the door, level the door, and make sure that it is square and properly shimmed, if needed. Below you will find the steps on how to install a new iron door.

Rough Installation of Doorjamb

  1. Make sure you do not remove the bracing bar on the bottom of the doorjamb for this step. It will help keep the doorjamb true and is helpful in the rough leveling phase. You will, however, remove it later on in the process. Also, there are flat plates welded to the doorjamb and these will need to face the interior of the home.
  2. Stand the doorjamb upright and place in the opening, making sure the mounting plates touch the wall. Use a level to make sure the doorjamb is sitting plumb and level.
  3. Use a pencil to mark the position of tabs on the wall, making them approximately ½ inch larger than the tabs on all side, giving you room to make adjustments later. 
  4. If you have an alarm, make a mark on the doorjamb where the wires will need to go. You will need to drill holes in these locations prior to completing the installation. Once you have these markings finished, place the doorjamb aside, and use a utility knife to remove the wallboard where you have made the marks. You want to completely remove the wallboards so that you can see studs, as the mounting plates need to be touching the studs.
  5. Once these areas have been removed, you are ready to install the doorjamb. Remember, however, to drill holes for the alarm wires. It is a good idea to double check the wire width to make sure you are drilling the right size holes.
  6. You can now move the doorjamb back into place, sliding the alarm wires in, if necessary. Make sure the mounting plates line up with the studs and double check to make sure the doorjamb is plumb and level. 
  7. Once you have checked to make sure the door is level and plumb, you can now secure using lag screws in four of the brackets – the upper two and the lower two on the sides of the doorjamb. Do not secure the top until the door is completely adjusted. 

Door Panel Installation

  1. Now that the doorjamb is installed, you can install the door panels. Make sure you have a 2 ½ inch block to sit the door on as you slide it into position.
  2. There are two barrels on the door hinge. One will be welded onto the door and the other welded to the doorjamb. A washer will go in between the two. There will also be a solid ¾ inch hinge pin that will hold each of the barrels together, and a hinge nut that secures the bottom of the hinge.
  3. After you have the door resting on the block, you can slide it into place, but make sure that the hinge barrels welded to the door are sitting above the hinge barrels that are welded to the doorjamb. You should have about 3/8 inch to ½ inch of space between the sets of barrels. 
  4. Once the barrels are aligned, you can place the washer on top of the doorjamb hinge barrel. You can leave the washer there until the hinge is in place, using a piece of tape to hold it until finished.
  5. You can now install the hinge pins. You may need to use a rubber mallet, as they will fit tightly. 
  6. Once you have hung both doors, you can remove the bracing bar that was mentioned earlier.
  7. Although the doors are hung, it is likely they are not sitting perfect. Shimming will be required to make sure the doors are lined up across the top and to remove any twists in the doorjamb. Place shims between the mounting brackets and the house frame to remove twists. You may need to loosen the lag screws to be able to move the frame. Shimming between the doorjamb and house frame can help the doors line up at the top. Do not stress, as this step can take some time to get the doors perfect.
  8. Now that the doors are hanging nicely, you can attach the doorjamb to the house frame. Make sure that all the brackets are securely bolted to studs.
  9. Open and close the doors to ensure they latch properly. You may need to make some minor adjustments with shims.
  10. Inject expanding foam to seal and insulate the space between the house frame and the doorjamb prior to replacing the trim. 
  11. You can now reattach the interior trim. If you want to paint the trim to match the new door, do this prior to installing.

Install Hardware

You can now begin installing the hardware. It is a good idea to do this now, as it can make adjusting the door easier when you go to install the sweeps and threshold. You will need to follow the directions of the manufacturer for this step.

Sweep and Threshold Installation

  1. For your convenience, the thresholds and sweeps are pre-cut by the manufacturer;however, you may need to make some minor adjustments. Double check the measurement between the finished floor and the bottom of the door. You should have 2 inches. If you have more than 2 inches, you will need to shim underneath the threshold until you only have 2 inches.
  2. Slide the threshold into place between the doorjamb and the door, making sure the threshold lines up with the inside of the doorjamb. You may need to use a rubber mallet, as it may be tight. 
  3. Make sure the unfinished part of the floor is not showing. If this is the case, you will need to install a threshold extension.
  4. Threshold Extension –Slide the doorjamb out of the way and measure the inside of the doorjamb. Cut the jamb extension to fit than install using silicone to seal it to the floor, and reposition the threshold. 
  5. Gently pry the threshold up so that you can run a bead of silicone between it and to floor. Apply pressure to completely seal the two together.
  6. Secure the threshold to the floor using screws on the adjustable riser on the threshold. Slightly unscrew each one, alternating, until all screws are removed, then set aside. Drill 2 inch wood screws into the holes about 8 inches to 10 inches apart. Reinstall the threshold riser. 
  7. You can now drill holes for the flush bolt, which are mounted in the t-astragal on the inactive door. Start by closing the door and then marking the first top hole. Push the top flush bolt up until it makes contact with the doorjamb, then stand on a ladder and place pressure on the inactive door in order to compress the weather-stripping. While applying pressure, mark the spot for the flush bolt, then drill a 3/8 inch hole in the doorjamb for the flush bolt. You can then push the top flush bolt into place. For the bottom flush bolt, lower it until it touches the threshold riser. Then, place pressure against the door to mark the spot for the lower flush bolt, which will ensure you have a tight seal for the weather-stripping. Drill the bottom hole and you can then install the trim plate.
  8. You can now apply a bead of caulk to the pre-cut door sweeps and place them into position. Do this by sliding the sweeps down on the bottom of the door until the rubber blades make contact against the riser. You want a tight fit. Use self-tapping screws and an electric drill to attach the sweeps to the door. Repeat this step for the other sweep.

Finishing Touches

At this point, your new door is installed and properly adjusted. You want to make sure that they swing freely and close tightly, so that you can now add the finishing touches.

Caulking

  1. Using fast-dry acrylic caulk, run a bead of caulk between the interior trim and the wall between the doorjamb and the trim.
  2. Run another bead of caulk between the doorjamb and the brick mold on the exterior.

 

Paint Touch Ups

  1. You may need to gently sand any scratches on the door with 220 grit sandpaper.
  2. Use black spray paint on any areas that you sanded or caulked. You can also use black spray paint to touch up the brick mold, screw heads, and any other areas that need to be black.
  3. To antique your door, use a deck brush with natural bristles and follow the steps in the figures below.
  4. To apply highlights to the paint, use a similar technique, but use a smaller brush, such as a chip brush. Instead of moving the brush in a swirling motion, just gently brush across the areas you wish to highlight. 
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