How to hinge and re-hang a door

Hinging and rehanging a door successfully is easy if you follow a few simple rules. And even more complicated jobs, such as changing the direction in which a door opens, are not as hard as they seem.

There is nothing more annoying than a door which is difficult to open and close. And although the trouble can usually be put right quite easily, neglecting such a door may cause more extensive damage which is costly and difficult to repair at a later date.

Before attempting any repairs, it is worth considering what hinges are available and how you hang a door properly. Indeed, when a door hangs badly, the hinges are often at fault: either they are fitted badly or the wrong ones have been used.

Choosing hinges

Plastic, nylon, or—better still—pressed steel hinges are suitable for light internal doors, but if you are fitting hinges to a heavy, outside door, use the strong type made of cast steel. If you want a finish which is rust free, jam free and decorative, brass hinges look good but are more expensive and less durable.

By finding out the thickness, weight and height of your door, you can estimate what size of hinge you require. For example, a lightweight door, 32mm thick, would need a 75mm X 25mm hinge whereas a heavier door, 45mm thick, might require a 100mm X 38mm hinge. Be careful not to buy a hinge which is too wide for the door as this will result in a weak, narrow strip of wood where the hinge is fitted. To find the size of a hinge, first measure its length and then the width of one of its leaves to the middle of the knuckle where it swivels.

Most doors are fitted with butt hinges and you can buy either the fixed or the rising variety. The rising butt hinge allows the door to rise as-it is opened but shut down closely on to a carpet or threshold as it closes. This means that though the door does not scrape against floor coverings, it will stop draughts and reduce fire hazards once it is shut.

Rising butt hinges are either right or left handed, so decide which way you want your door to open before you buy a set. Avoid confusion by getting the difference clear in your own mind.

Marking and fitting

Before you fit the hinge decide which side you want the door to open. Panelled doors can be hinged on either edge but most modern flush doors can only be fitted with hinges on one edge.

On some doors the hinge positions are marked on the edge of the door and these areas are usually reinforced, so it is advisable not to try to fix hinges to any other spots.

Once you have decided which edge of the door is to be hinged, arrange it so that it is resting on the opposite edge. Support the door by wedging it into a corner, cramping it to the leg bf a table, or by holding it in a vice.

The best positions for the hinges are 215mm from the top of the door and 225mm from the bottom, but make sure that this does not leave them over any joints or the door may be weakened.

Use a marking knife and try square to mark the hinge positions on the door edge, starting from the knuckle edge where the hinge will swivel. Mark across all but 6mm of the edge then continue on to the face of the door, marking the thickness of one hinge leaf.

Next, open one of the hinges and lay it in position on the door edge to check that the lines you have drawn are accurate. Hold the hinge in position and use a marking knife to mark each end. Then scribe the width and depth of a hinge leaf on to the door edge and frame.

Cutting out

The hinge recesses are now ready to be cut out. Use a bevel edged chisel and start by chopping downwards across the grain in a series of cuts 5-6mm apart. Leave a thin uncut border of about 2-3mm around the three edges. Now hold the chisel flat, bevel side up and pare away the chipped-up timber. Finally, keep the flat side of the chisel parallel to the door edge and clean out the rest of the recess.

The hinge should now press firmly into place flush with the surrounding timber. You may have trouble with some types of hinges which are bent slightly due to pressure in their manu- facture. If this is the case, pare away a further l-2mm from the recess.

Fixing hinges

Once the hinge is comfortably in position, carefully mark the screw holes with a sharp pencil then remove the hinge and remark the screw centres with a centre punch. Try to mark these a little off centre—towards inside of the recess—so that once the screws are inserted, the hinge will be pulled snugly into position.

Drill pilot holes to the depth of the screws and then clearance holes deep enough for the screw shanks. For heavy butt hinges use No. 7 or No. 8 X 38mm screws. Insert the screws so that they finish level with or slightly below the hinge plate.

If you are using brass screws, put in a steel screw first. This will cut a thread in the wood and avoid the possibility of shearing off or damaging the soft brass screw heads.

Fitting the door

Position the door in its frame by supporting the base with wooden wedges made from offcuts. Both door and hinges should be in the fully open position unless you are using rising butt hinges, in which case they should be closed.

With all types of hinge, make an allowance at the base of the door for any proposed floor covering and adjust the gap as necessary by altering the positions of the wedges. When you are satisfied that the door is in the right place, scribe around the hinges with a marking knife to mark their positions on the door frame.

With the door removed from the frame, mark out the hinge recesses— their length, width and depth—accurately with a marking knife and adjustable try square. Use the same technique to cut the recesses as you used for those on the door.

Replace the door and position it exactly using the wooden wedges, then tap the hinge leaves into place in the waiting recesses. Finally, mark and pre-drill each screw hole then insert one screw in each hinge so that you can check that the door opens and closes properly. If it sticks at any point, make minor adjustments by chiselling away more of the rebates before you drive home the remaining screws.

Sticking doors

If a door sticks and you can find nothing wrong with the hinges, it may be that part of the door frame has swollen. Where the swelling is slight and there is plenty of clearance between door and frame, investigate the possibility of bringing the swollen part away from the frame by either packing or deepening one of the hinge recesses. Be sure to make only the slightest adjustments in one go, or the door may stick elsewhere around the frame.

Where the swelling is more severe, you have no choice but to plane off the excess and redecorate the door. The planing can be done with the door in situ providing you first wedge the base to take the weight off the hinges.

Older doors and those particularly exposed to damp may warp or become loose at the joints, causing them to fit badly in their frames. In the case of slight warping, one answer is to make a small adjustment to one of the hinge positions so that you take up the twist. Do this on the frame—not on the door.

However, a more satisfactory solution is to remove the door so that you can cramp and strengthen the frame. Take off all the door furniture—the hinges, knob, lock, key escutcheon— place it flat on a workbench, then cramp the frame square using a sash cramp with a long bar.

Where gaps appear in the joints, scrape out any dust, accumulated grime and old glue with a chisel or knife. Then bring the joints together by cramping across the frame in two or more places. Use softwood offcuts to protect the door from being bruised by the cramps.

Next, drill out the old wedges hold ing the tenons at each frame joint to depth of 75mm ; use a 15mm twist drill bit. Make up some 85mm lengths of 15mm dowel with longitudinal cuts in them to allow for compressing and chamfers at one end to give a snug fit.

Liberally smear each piece of dowel with external grade waterproof woodworking adhesive then drive them home into the drill holes with a mallet. Check that the cramps are still holding the frame square by measuring across the diagonals—which should be equal—and leave the adhesive to set. When it is dry, cut off the excess dowel with a tenon saw and finish the edges in the normal way.

Repairing a damaged stile or rail

If a stile or rail is split, it is usually possible to open this up, force in some adhesive then cramp it closed again. In this case, where necessary, place some newspaper between the split and the cramp protective offcuts to stop the latter from sticking to the frame. When the adhesive has set, fill any remaining cracks with wood filler and finish with a block and glasspaper.

Very badly damaged or rotten areas must be cut out completely and replaced with new timber. Using an adjustable bevel and marking gauge, determine and mark out the extent of the damage along the frame. Mark the width of the damaged area with a marking gauge on the face of the door.

You must now cut out the timber. Mark out and cut a replacement section, making it slightly wider than the frame so that it can be planed flush after fixing. Secure the section with woodworking adhesive and oval nails, the latter punched well below the surface level.

If the replacement section is over a joint, the tenon in that joint will have been seriously weakened by the repair. The remedy is to drive two or three dowels through the new timber into what is left of the tenon. Drill and glue the dowels as described above.

Changing direction

It is often useful to change the direction in which a door swings—to make more space in a small room for example —or to hang it from the opposite side of the frame.

Making a door open in the opposite direction involves removing and resit-ing the door stop, altering the hinge rebates and possibly changing the door furniture. You may or may not have to change the hinges, depending on what type you have. Ordinary butt hinges can simply be used the other way up.

How you go about the job depends on whether your door stop is simply planted—nailed to the frame—or rebated into it.

Removing a planted stop: Remove the door from the frame and clear the space around you. Then use a blunt, wide chisel and mallet to cut into the joint between stop and frame and lever the latter away. The stop is bound to be securely fixed and you may have to use considerable force. The job becomes easier when you can insert the claws of a claw hammer and ease the stop away, working upwards from the base of the door.

Once the door stop has given way, remove any old glue or chipped wood with a chisel, plane and glasspaper. Removing a rebated stop: Start by measuring by how much the stop protrudes then mark this amount down and around the outside face of the frame with a marking gauge.

Next, take a tenon saw and make a series of cuts 12-18mm apart in the top corners of the door frame. Remove the waste between these with a wide chisel in the same way as you would when producing a halving joint. This done, you can insert a rip saw or power saw and cut downwards through the remainder of the door stop. Afterwards, plane the cut timber flush with the rest of the frame and use a chisel to clean up the corners.

Rehanging

When you come to rehang the door, the hinge recesses may well have to be moved. Do this by chiselling them across to the other side of the frame. Then make up wood blocks to fill the now unused parts of the recesses and pin and glue these in place.

Refit the door stops—or make up new planted ones in the case of rebated stops—in accordance with the new 8 door position. Make sure that the stops are firmly pinned and glued. ‘E If the door lock or latch is handed, g you must exchange it for a new one m and fit it according to the manufacturer’s instructions. Alter the position of the striker plate and make good the old recess as you did the hinge recesses. Finally, rehang the door as described above; start by fitting the hinges.

Changing sides

If you decide to change the side on which the door hangs, all the above operations will be necessary and you will have to swop over the door furniture to the other side.

As this is often handed, make sure that it is still suitable for the new door opening. Indeed, this is a good time to exchange the furniture for a new set.

Make good the holes left in the door by driving in tapered and glued wood blocks, cut oversize so that you can plane them flush with the surface. When you have done this, fill any remaining gaps with wood filler and repaint the door.

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