Part 3
You have now organised yourself with the new lining, tools and sundries.
First, let’s concentrate on the door lining itself. You have opened your pack which should contain three large pieces of wood and three skinny pieces of wood. If you are lucky there will be four screws as well.
Familiarise yourself with the components. The two short pieces are for the head and the long pieces are for the vertical jams.
Grab the short wide piece and you will see the ends are machined with a channel of the same thickness as the jams. The end of the Jams fit into each of the channels or rabbets.
Compose the Door Lining Ready for Installation
Layout the components of the lining so to make the shape of the letter N. Short piece to the top and the jams to the edge. Take the door stops and put to one side for later as you will need these when hanging your door.
- Cut left and right door jams to length
- In the channel apply a little PVA or Cascamite wood glue
- Use your battery screwdriver and screw the head to the jams
You now have a complete door lining ready for installing into the hole.
You have the door lining together and now you need to place it into the hole where the door is to be installed. If you know what side the new door is to be hung and the direction of opening you can continue.
I start by placing the lining in the hole. Using a short spirit level adjust the head so it is level and flush with the face side of the wall. Be careful not to put too much strain on the joints as the Jams will be wobbly!
Fix That Jam into Place
Assuming the floor is level and the jams are the same length wedge the head just above the jam as to help hold the jam. If using lost head nails nail the head in line with the face of the wall. At this stage do not hammer the nails fully home in case of adjustment.
Old woodworkers never die, they just pine away…
Now grab the long level and level the jams and also align with the face side of the wall. Level the hung side first which is where the hinges will be placed.
Remember to be sure to not fully drive the nails home at this stage just in case you need to readjust.
Clever Packing
No, we’re not going on holiday but the little plastic wood things that fill the gap to allow you to accurately fix the lining.
Packers come in all shapes and sizes but the job it has to do is basically the same. There are Plastic Flat Packers, Plastic Wedge Packers, Plastic Horseshoe Packers, Wooden Flat Packers and Wooden Wedge packers.
I only use wooden packers as we make our own flat and wedge style packers. I feel that the wooden packer is easier to use and easy to trim. The beauty about a wooden wedge packer is that if you use two opposing each other they become adjustable and stay parallel.
QUICK TIP: Where to Place The Packers (Shims)
You already need to hold more stuff than you have hands! Just place the packer just above the nail so the packer does not drop to the floor. If using wooden packers and little wood glue will stop the packer coming loose over a period of time.
QUICK TIP: The Spirit Level Advice (Pic)
Longer the spirit level the better it will perform. On a spirit level, there are two lines on the vial which aid in finding the centre. It is important that the bubble is not just in between the lines but in the centre for the level to be level.
Check the Levels
Now you have a provisionally fitted door lining. So before you progress to the door hanging just get that level and check the head and the jams for plumb and the corner for the square at the head. If you get this part right you will find the door fitting much easier.
“Start Right Finish Right”
The content above may seem long-winded, but I really wanted to cover everything that you may come across in installing a door lining or frame.
Now Let’s Hang a Door
Hanging an external door is similar to hanging an internal door. Many of the points in this tutorial can cross over to all door hanging projects. The goal is to learn some practical skills.
New Doors Purchased off the Shelf
You may have seen that perfect door which you desire for your house. The problem with this decision is that they come in fixed sizes. You may have to trim these doors to size which will make you the fitter or DIY installer have more to do.
These doors are often poorly jointed in the corners. If you find that you have to trim a lot off the door you are at risk of cutting through the jointing system. You do not want to cut through and jointing which holds the door together.
Made to Measure Doors / Bespoke
If you have ordered your doors from us at Wallybois then you are on a home run! You should not have to trim that door to fit the door lining or frame.
You Need a Leading Edge!
Every door that has a square edge that has to fit into a rebate will need a leading edge. This is a skill that has been practised for many years by artisans from the days of the door.
What is the leading edge?
The leading edge is the angled edge of a door that is created by a Hand Plane
What is the Purpose of the Leading Edge?
The leading edge gives you the door clearance to allow you to have a close-fitting door. If you decide not to apply a door leading edge. You will have to fit the door loosely with big gaps around the door.
Logically the door has a cross-section that is greater from corner to corner than edge to edge.
QUICK TIP: Hide those Nails
You can hide the head of your nails or at least reduce the amount showing. By being strategic as to the location of the nails. One sensible location is behind the door stop. When the door has been hung you can cover nail heads with the door stop.
What Hinges Should I Choose?
There are so many options regarding hinges for doors but your choice should not be guided by your previous regional preferences. What I mean by this is that if you live in France you should consider using the hinge of your region. The same applies to the UK and the United States. I have all to often come across English hinges on French doors which only cause issues when you want to replace as it is awkward to acquire.
How to hang a door on English Butt Hinges?
As an Englishman luckily living in France I have hung numerous doors on ‘English Butt Hinges’. These hinges are perfectly serviceable and come in many different styles and levels of quality. It is beneficial to seek good quality stainless steel or brass but the mild steel will suffice if on a budget. I have found these to rust and wear leaving metal grinding dust on the door.
These English Butts are available in a loose pin format which makes the door removable without removing the screws from the hinges.
How to Chop in an ‘English ‘Butt Hinge’?
The Butt Hinge has to be cut into the edge of the door and the door lining. The purpose for chopping in the hinge is for the hinge not to interfere with the door and reduce the gap on the hung side.
Another very good reason to chop the hinge in the woodwork is that the edge of the door is supported on the edge of the hinge and not just the screws.
- Compose all the required hinge components and tools
- Take hinge and place on door hung side and mark around the door with a sharp pencil or marking knife Use the Barrel of the hinge as a stop guide.
- Using a sharp chisel and mallet chop out clearance to the thickness of the hinge
- Screw hinge to the door being careful that no obstructions make the door bind.
- Repeat for the three-door hinges
- Match the hinge positions on the door onto the hung side door jam.
- Repeat the three corresponding hinge positions.
French Hinge for doors
How to hang a door on French drop-on Hinges?
In France, we use a different hinge to the butt hinge even though they are available but non-compatible sizes.
The French door hinge is reasonably priced if you buy from the right store. For instance, I can buy a 110mm door hinge from Bricoman for 1e30c. In Mr Bricolage or Bricomarché at the (time of writing) are only sold in pairs for twice if not three times the price.
These hinges make removing the door once hung easily due to their ‘drop on’ pin design.
The French Hinge comes in two main types ‘Square End’ or ‘Round End’ The square end is installed using a chisel just like the English Butt. The Round End is fitted with the help of a router and fence or jig.
- Compose all the required hinge components and tools
- Take hinge and place on door hung side and mark around the door with a sharp pencil or marking knife. Use the Barrel of the hinge as a stop guide.
- Using a Router with a cutter the width of the hinge and a fence fitted machine clearance to the thickness of the hinge. Tip: use a block of wood and clamp to act as a stop for the router.
- Screw hinge to the door being careful that no obstructions make the door bind.
- Repeat for the three-door hinges
- Match the hinge positions on the door onto the hung side door jam.
- Repeat the three corresponding hinge positions.
Prepare the Hung Side for Hinges
- First, put a lead on the hung side or the door
- Put the door on the edge holding it with a door vice or workmate bench
- Using your tape measure first mark the centre of the door edge of the hung side
- Mark the door 150mm (6”) from the top and from the bottom
- Chop in the hinges refer to our hinge guide in this tutorial
- Screw fix the hinges to the door. Be sure that the heads are flush so not to bind the hinges
Prepare the Hung Side of the Frame or Lining for Hinges
- Measure from the top of the door and transfer the hinge positions to the door lining
- Chop out the hinge positions with a chisel. We have a tutorial on this
Wooden Door Need Room Too?
Anything made from timber will grow or shrink with the seasons. Central heating will also have an effect on the lumber used to make the doors. It is important to allow for this movement.
Old Stone Houses Like to Boogie
Yes, they do as they are all ways of moving with the land they are built on. Modern homes built from concrete blocks or brick are normally built on deep foundations. I know in the UK the building control monitors construction so expect anything built from 1970 is built on strong concrete footings.
Our old French House inbuilt from local stone and infilled with small stone and clay. As a result ‘this Old House of Mine!’ moves considerably during the seasons so I have to make additional allowance for the door jam clearance.