DIY Network

Convert a Window to a Door: Exterior Demolition and Notching the Brick From "Weekend Remodeling" episode WKR-211

	In this week's episode of Weekend Remodeling, host Fuad Reveiz will show you how to transform an existing set of windows ...
	into a beautiful new entryway!
	Exterior doors come in a wide range of choices. For this particular project the homeowners chose a three-panel door that matches the rest of the house.

Host Fuad Reveiz begins this phase by determining where the new door will go and by marking the brick where the exterior demolition will begin.

This is an intermediate level project and rated 4 on a "difficulty" scale from 1 to 5, with 5 being the most difficult.

Materials:

Pre-hung 3-panel door
Bricks
Mortar
Shims
Miscellaneous lumber (including OSB plywood)
Nails
Screws
Trim
Caulk
Paint

Tools:

Chop saw (with a diamond-tip blade)
Trowels
Joint tool
Flat pry bar
Tape measure
Level
Utility knife
Reciprocating saw
Gloves
Mask
Safety glasses
Hammer
Chisel
Drill
Nail gun
Painting supplies

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	Figure A
	Figure B
	Figure C

1. To notch the brick for the window removal, start by measuring over 1-1/2" and draw a line using a level down both sides of the window (figure A).

2. Next use a quicky saw with a masonry blade to cut the brick (figure B). You'll need this room for the new door, and it'll make taking the windows out much easier.

   Safety Alert: Please be sure to wear safety goggles when cutting brick.

   Tip: Cutting brick creates a tremendous amount of dust, so be sure to use a tarp to keep it somewhat under control.

3. Once both sides have been cut, use a hammer drill to remove the bricks underneath the window (figure C). Getting the brick started requires some effort and muscle, but once you get the first couple out they start to fall fairly easy by just placing the hammer drill in the mortar joints.

4. Follow along the mortar joints to loosen the bricks, and then pull out the pieces by hand.

5. Reveiz decided to leave the bottom row of bricks intact since the sub-floor inside is higher than this anyway, and that will give him a head start when he comes back to lay the row lock under the threshold.
   Tip: If you place the hammer drill in the mortar joints about every three bricks (figure D) or so it will give you the best result. They'll just sort of peel right off.

6. To remove the window, use a nail punch to push the finish nails through the brick molding. Simply drive the nails into the studs they were attached to, and then take a utility knife and cut the caulk seal across the top of the window. With all the nails pushed through, the window has nothing holding it in place.

7. Have one person on the inside "push" the window out while two of you catch it as it comes out (figure E). This is actually the easiest part of the job!

8. Before you move on, you need to address the bricks that were cut on both sides of the opening. It's not going to look good if you put the door up against these, so they have to come out and some new ones have to go in.

   Figure D

   Figure E

   
   

   	Figure F
   	Figure G

9. Since you're going to be creating more dust, put some plastic up over the opening to keep it out of the house. Use a staple gun to create a tight seal all the way around.

10. Use the quicky saw to cut away the horizontal mortar joints between the bricks, and be sure to switch to a diamond-tipped blade since these cuts need to be more precise (figure F).

    Note: Accuracy is very important and doing this correctly will make "toothing" out the brick much easier, and it will keep you from breaking other bricks in the process. It takes about 30 minutes to make all the cuts for each side. Know that the saw gets heavy when you have to make these types of cuts at this angle. It's definitely a hard workout!

11. Once all the joints have been cut, chipping out the unwanted bricks is next. Use a hammer and masonry chisel and work up the wall. Be careful not to break the bricks you want to keep.

    Tip: The trick is to make sure and not only remove the brick but the old mortar as well. This way you'll have the room to install the new ones when the time comes.

12. If you do this process correctly, every other brick is left untouched and the "tooth" pattern (figure G) becomes apparent.

13. To close up the opening leave the lower wall and studs that were under the window so you'll have something to attach the 1/2" OSB plywood to for the night.

The first day of work is completed and we're right on schedule. In the next segment Reveiz will finish opening the wall and install the new door.

RESOURCES :

Masonite Doors
Website: www.masonite.com