On the afternoon of Thanksgiving i decided to take the plunge and replace my front door. I popped off the trim around the inside and outside, removed the long screws from the hinge and jamb and the door just about fell out. There was no insulation between the door and the wall.
Here’s a photo that shows the old door from the outside.
Seth and Kahn arrived about a half hour into the project and we had our Thanksgiving steaks so i took a break from the door. Friday i got spray insulation in and trimmed the interior. today i worked on the outside.
I messed up three things. First, i ordered a door for a wall based on 2×6 construction. Well, there are parts of my house framed with 2×6 but this isn’t one of them. So the door frame would have to stick beyond the wall on the inside or extend outside further. I chose outside.
The door came with some wood blocking to make sure the kickplate stayed secure. I didn’t remove those and so the door sits about a half inch higher than it needs to. I still need to support below the kickplate so it is more stable.
When putting in the lock hardware i carved out the part of the door to receive the plate that surrounds the latch. Once i read further into the instructions i found out that i could have just removed the plate.
Here you can see the gap between the outside trim and the wall sheeting.

You can also see two switches – one was for the light mounted just above and to the right of the door. The other leads to the motion sensing lights in the carport. There is another switch in the carport for those lights so i intend to circumvent this switch entirely. The one for the light at the door i changed to motion activated.
To easily attach trim to frame in the door i cut a number of 6 inch long 2×4s and mounted them at 16 inch intervals behind the existing trim.

I then used some small galvanized nails to attach MDF boards that are almost 6 inches wide and have been primed on three sides.

The other side of the door took a little more time because of the wiring but i changed out the light fixture with a more modern one and installed a motion detecting switch to help with hands free light and making sure the light goes out when not needed.

I need to now run some of the MDF through my table saw so that it can be slipped in behind the facade trim to complete the boxing of the door.

So aside from the last few trim pieces i also need to brace the kickplate and wire in a doorbell chime inside the house (once i have one to install)
If you look at the last two pictures you can see the cabinet lighting that i’m working on in the background,