DIY Network

Energy-Efficient Door Replacement From "Ask DIY Home Improvement" episode DADH-203

This new exterior door keeps drafts away.

If you want to save money on your home heating bill, consider replacing drafty old doors. It's a project that isn't as difficult as you might suspect.

Q: (Jake, Chicago) Stand inside an exterior door of our home, and you can feel the wind blow through the gaps around it. I want to replace the doors, but have no idea where to start. Can you help?

A: (Licensed Contractor, Brad Staggs) We replaced an old wooden door desperately in need of a paint job with a steel door that includes a full-length window. It allows a lot of light to come into this small kitchen, but not a lot of cold air. The 24-gauge galvanized steel door won't warp, crack or peel. Because this door is made 1" shorter and 1" less in width than the old door, we were able to slide it right into the old door jamb.

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	Figure A
	Figure B
	Figure C
	Figure D
	Figure E

1. It's easy to measure for a replacement door. Simply measure the width of the door in three places: top, middle and bottom. Also measure the door height on the left and right sides. Use the shortest measurement of each for the size of the new door. Before purchasing your new door, you also need to determine whether you want the handle on the left or right side.

2. To remove the old door, first score the paint on the trim, then use a prybar to remove. Use a screwdriver and hammer to knock out hinge pins (figure A), lift the door off the hinges and carry it out of the way.

3. Use a prybar and hammer to lift away the old threshold and remove the screws that attach the old hinges.

4. In this demonstration, the old door frame isn't level on top, so a new header is created from a piece of redwood (figure B). A level is used to ensure the piece is straight.

5. Add thin wood pieces to both sides of the door to shim to correct dimension for new door. Follow manufacturer's instructions to determine how many shims are needed for the door.

6. Remove door from packaging and test fit. If the door fits into the old jamb, simply attach the steel frame around the new door directly to old door jamb.

7. On the inside of the frame, attach eight security screws through the pre-punched holes in the frame (figure C). Do not overtighten screws -- which could distort frame.

8. Follow manufacturer's instructions for installing the included lockset and deadbolt.

9. Add weatherstripping around door (figure D), then test to make sure door still closes smoothly.

10. You might consider the addition of latex caulk on the outside edge of the threshold and the bottom of the door frame.

11. Attach old door trim. If old door trim doesn't fit, you might need to cut new wood pieces (figure E).

12. Finally, paint the door (this one is pre-primed). Wipe to remove any dust or grime, then apply exterior paint on the exterior side; interior paint to the interior side.