How to Install a Solid-Wood Exterior Door

Ready to swap out your old, drafty entryway door with a new energy-efficient one? We’ve got you covered. In this article, we’ll explain how to install a solid wood exterior door. It’s a manageable project for homeowners with moderate carpentry skills and careful attention to detail. In case you want a visual guide, we’ve also included a video featuring This Old House general contractor Tom Silva as he demonstrates the installation process, offering expert tips and techniques along the way.

Preparing for Installation of a Solid-Wood Exterior Door

Before diving into this project, you’ll want to prepare your workspace and gather your tools. This will help the installation process go smoothly. The list of tools you need are below:

Removing the Old Door

The first step in installing a new door is removing the old one. Here’s how to do it:

1. Use a hammer and slotted screwdriver to tap out the hinge pins from the old door.
2. Remove the door from its frame.
3. Cut along the outer edge of the interior door casings with a utility knife to break any paint or caulk seal.
4. Take off the side and head casings using a hammer and flat bar.
5. Use a reciprocating saw with a metal-cutting blade to cut through the nails holding the side and head jambs in place.
6. Pry the jambs out of the doorway opening.

Installing the New Solid-Wood Door

After removing the old door, you’re ready to hang the new solid wood exterior door. To keep your new door energy efficient, make sure it fits and seals properly during the installation process. 

Before setting the new door in place, prep the space by following the steps outlined below:

1. Check that the threshold and side casings are level. Use shims if necessary to create a level surface.
2. Fill any voids around the doorway opening with minimal-expansion insulating foam. This will help to keep the cold air out.
3. Apply a thick, continuous bead of acrylic-latex caulk along the threshold to create a watertight seal.

Pro Tip: Tom Silva, general contractor on This Old House, advises checking whether you can reuse the existing threshold: “The old one is actually in pretty good shape. It’s not rotted. So I’m gonna keep it. Now, it’s level so we can set the aluminum threshold that comes on the door right on top of it.” Reusing a solid existing threshold can save time and preserve the original look of your entryway.

Setting the Door in Place

Now it’s time to position the new pre-hung door. To do this:

1. Set the pre-hung door into the opening, tipping it up and into place.
2. Center the door in the opening and check the side jambs for plumb using a level.
3. Secure the door temporarily by nailing through the exterior casings and into the jambs.

Check the Rough Opening First: According to This Old House Magazine, before setting the door, place a 4-foot level on the floor at the base of the opening. If the floor on the hinge side is lower than the latch side, slip a pair of shims — thick ends pointing in opposite directions, narrow ends overlapping — under the level nearest the hinge jamb and move them together or apart until the bubble is centered, then tack them to the floor with a finish nail. Also check the trimmers for plumb and verify they are square to the wall using a framing square.

Shimming and Securing the Door

By shimming your door, you can make small adjustments so that the door is plumb, allowing it to function properly. Follow these steps:

1. Remove the door from its frame by tapping out the hinge pins.
2. Pull out the weatherstripping along the side jambs.
3. Place the level on the jamb, using it as a straightedge. This will help you to determine if there are any gaps. 
4. Insert wood shims behind the side jamb on the hinge side of the doorframe where necessary.
5. Use a level again to check the jamb to make sure it’s perfectly straight and not bowed.
6. Secure the jamb by shooting 2½-inch nails through the jamb and shims into the house framing. This will be a temporary hold until you can grab your screws for a permanent hold.
7. Drill screw-shank clearance holes through the jambs, positioning them where they’ll be hidden by the weatherstripping.
8. Drive 3-inch decking screws through the holes in the jambs and into the house framing.
9. Repeat the process for the latch-side jamb.

Pro Tip: When shimming, use pairs of tapered shims stacked in opposite directions so the combined thickness stays even. As demonstrated in a This Old House project, Steve explains the technique: stack one shim tapered one way, then place another on top going the opposite direction—”So now the stack is even in thickness no matter where I put them.” Then spread the shims apart to fine-tune the gap between the jamb and the rough opening.

Finishing Touches To Install a Solid-Wood Exterior Door

Once the door is in place, it’s time to insulate, seal, and add the finishing touches to your new solid wood exterior door.

Insulating and Sealing

Maximize your new door’s energy efficiency by insulating it. The steps to do this include:

1. Cut the shims flush with the jambs using a utility knife.
2. Spray insulating foam into the voids around the jambs.
3. Fill any large voids with fiberglass insulation for added thermal protection.
4. Reattach the weatherstripping to the jambs.

Pro Tip: According to This Old House Magazine, apply a single thin bead of minimally expanding polyurethane foam to the gap between the door jamb and the framing, then allow the bead to expand and cure for one hour before adding more. Repeat until the cavity is completely filled. Do not fill the gap with too much foam too quickly — otherwise, the jamb could bow and bind the door.

Installing Interior Trim

To complete the interior look of your new door, nail new wood casing around the interior of the door and caulk the joints between the new frame and the exterior casing to prevent air and water from entering your home.

Finishing the Door

As Silva mentioned in the video, if you have an unfinished door, you’ll want to protect it against the elements. Here’s how: 

1. Clean the door thoroughly with a mild detergent and allow it to dry completely.
2. Sand the door lightly with fine-grit sandpaper for a smooth surface.
3. Apply an exterior-grade finish to both sides and all four edges of the wood door. This could be a stain, paint, or clear sealer, depending on your preference and the door manufacturer’s recommendations.

Pro Tip: After hanging the finished door, This Old House general contractor Tom Silva recommends patience with the curing process: “Wait for the door to really dry. It’s dry to the touch right now, but I want it to dry for about 24 hours. Sand it lightly with some 220 paper, wipe it off with a damp rag. Make sure there’s no moisture on the door. And give it another coat.” He advises repeating this sand-and-recoat process at least two times for lasting protection.

Additional Tips for Maintenance

Maintaining your new solid wood door will help it last for years to come. Here are a few tips:

• Clean the door and its hardware periodically using a mild detergent and water. Avoid using harsh chemicals that could damage the finish or hardware components.
• Lubricate the door hinges and locking mechanism with a silicone-based lubricant annually to continue its smooth operation and to prevent rust or corrosion.
• Regularly inspect the door for signs of wear, such as cracks or fading in the finish. If you find any issues, address them by applying touch-up stain or paint as needed to protect the wood.