New Exterior Slab Door?

Old 03-25-21, 08:49 PM
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Question New Exterior Slab Door?

It seems most exterior doors are sold as prehung kits with the doorframe and brickmold assembled on it?
Whereas new interior doors are often just sold as slab doors alone...

But, could I simply replace an exterior metal door (steel faces sandwiching a wooden perimeter edge) with a new one that isn't prehung? So that I would just install it like an interior door (chisel out insets for the 3 existing hinges into the wooden edge and then screw them in there)? And not even have to touch the existing brickmold, doorframe, or interior door trim?
Old 03-26-21, 02:05 AM
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While I've seen exterior wood slab doors for sale I don't think I've ever seen a steel or fiberglass door slab for sale. Wood doors can be trimmed if needed to fit but there are very few options for altering a steel door's size.
Old 03-26-21, 05:07 AM
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It's possible to replace a slab only for an exterior door. BUT, it must from the same manufacture and the same model.
My son is still waiting for his replacement slab that was defective from Masonite. They are able to just replace the door itself but is has to be the same model. They two weeks ago they had a replacement. They told him those particular doors had a history of problems and would be replaced with an updated version. They sent the old style. He refused it, as advised by the installer and is waiting for the up dated version.
Old 03-26-21, 05:28 AM
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The problem is that exterior door slabs are slightly different sizes from different mfg's and typically they come premortised. Their mortise measurements are all different as well. You would think it would be standard but its not. And even within a brand the sizes vary depending on the age of the door. Just went through this with ThermaTru. Old door size was 35 7/8 x 79 5/8. New slabs are 35 5/8. They could provide a slab the right size but it would take 2 months and would cost more than a whole new door. So which route do you think I took?

Typically its time to replace the entire frame anyway. Exterior doors get weathered from rain and the threshold wears from use so it usually makes sense to replace the entire door. Plus you aren't saving a lot. A new door slab is about $150-200 (plain primed steel) whereas you can usually get the whole prehung for a few bucks more. And stores don't stock exterior door slabs in very many styles. Usually just one or two.


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