How to Replace a Hollow Door How to Replace a Hollow Door

What You'll Need
Safety goggles
Screwdriver
Door wedges
Plane
Drill kit
Measuring tape
Carpenter's pencil
Hammer
Medium-sized chisels
Although hollow doors are popular with many homeowners because they are so easy to install, they do have one major drawback: they are more fragile, therefore tending to break much more often solid core doors. A hollow door can only take so much abuse before natural wear and tear degenerates into outright disrepair, so what do you do when your hollow interior door has been damaged beyond all restoration? 
Determine What Needs to Be Replaced
When door replacement becomes necessary, the first thing you need to do is to check the frame and make sure that there is no outstanding structural damage requiring it to be replaced as well. Replacing a frame can be a tedious and time consuming process, however installing a new door into a damaged frame can cause even more problems in the long run. 
So, when checking a wooden frame for existing damage, do a thorough inspection for rot, moisture damage, and any seams or cracks showing in the wood. When checking a metal frame, be sure that it is not rusting or warped out of shape. Be sure that the hardware reinforcements are sound--checking the welds, hinges and hinge reinforcements. If any of these areas appear to be damaged or unsound, a new frame is probably necessary in order to ensure proper hanging of your new hollow door.
Replacing Your Hollow Door
Tools and Materials Needed
Safety Goggles
Screwdriver
Door Wedges
Plane
Drill Kit
Measuring Tape
Carpenter's Pencil
Hammer 
Medium sized chisels
Step 1--Remove Damaged Door
Stand on whichever side you hinges are located. Working your way up from the bottom hinge, remove each hinge pin carefully--tapping stubborn pins lightly to loosen them. In order to prevent injury, have someone hold the door for you as you remove the final pins. 
Step 2--Size New Door
Lay the old door on top of the new door. Trace outline of the old door onto the new one using a carpenter's pencil. Plane new door to size, making sure that there will be 1/16 of an inch around the sides and top, as well as an 1/2 inch at the bottom for frame clearance.
Step 3--Attach Hinges
Lay the old door back on top of the new one and mark the positions where the hinges should be attached. hisel shallow recesses for the hinges, first outlining with the chisel, then chiseling out hinge-deep spaces. Use the chisel on a low angle to prevent digging deeper than necessary. Scrape away remaining wood. Using the original hinges if possible, place the hinges and make sure the hinges are level with the door. Use the drill to screw pilot holes and attach hinges to door.
Step 4--Install Door Knob and Latch
If at all possible, reuse the original door knob and latch as well to make things easier. Mark off all positions by taking measurements off of the old door. Paint the new door if necessary, making sure to paint the top and bottom of the door as well to block off any moisture from setting in.
Step 5--Hang the Door
Check door for fit and be sure therre are no loose hinge pins. Check swing and closure, making adjustments as necessary.

A hollow door is easy to install. However, it does have one major drawback: It is somewhat fragile and therefore more susceptible to damage than solid doors. Hollow doors can only take so much abuse before natural wear and tear degenerates into outright disrepair.

When door replacement becomes necessary, the first thing you need to do is to check the frame and make sure that there is no outstanding structural damage. Installing a new door into a damaged frame can cause even more problems in the long run. 

When checking a wooden frame for damage, do a thorough inspection for rot, moisture damage and any seams or cracks in the wood. When checking a metal frame, be sure that it is not rusted or warped. Inspect the hardware reinforcements; check the welds, hinges and hinge reinforcements for soundness. If any of these areas appear problematic, you should probably install a new frame in order to ensure proper hanging of your new hollow door.

Step 1 - Remove the Damaged Door

Stand on whichever side your hinges are located. Working your way up from the bottom hinge, remove each hinge pin carefully. Tap stubborn pins lightly to loosen them. In order to prevent injury, have someone hold the door for you as you remove the final pins. 

Step 2 - Size the New Door

Lay the old door on top of the new door. Trace the outline of the old door onto the new one with a carpenter's pencil. Plane the new hollow door to size, and make sure you leave 1/16 inch around the sides and top and 1/2 inch at the bottom for frame clearance.

Step 3 - Attach Hinges

Lay the old door back on top of the new one and mark the positions where you should attach the hinges. Chisel shallow recesses for the hinges. (First chisel the outline. Then dig out hinge-deep spaces.) Use the chisel on a low angle to prevent digging deeper than necessary. Scrape away remaining wood. Using the original hinges if you can, place the hinges and make sure they are level with the door. Use the drill to screw pilot holes and attach the hinges to the door.

Step 4 - Install a Doorknob and Latch

If possible, reuse the original doorknob and latch for an easier installation. Mark off all positions by taking measurements from the old door.

Step 5 - Paint Your Hollow Door

Paint the new hollow door at this time. Make sure to paint the top and bottom of the door as well, in order to block off moisture.

Step 6 - Hang the Hollow Door

Check the door for fit. You shouldn't find any loose hinge pins. Check swing and closure. Make adjustments as necessary.

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