Door Repair - Replacing Broken External Frame Part

 We havent written in our blog for over a month, although we still have been busy with projects.

One project we completed recently, was for a returning client that requested a door repair.

A powerful wind storm had taken hold of his storm door and the door closer failed because the screws that hold the bracket to the frame were not long enough to effectively hold the door to the frame.

The result is what was pictured here, the frame breaking in half, exposing the poor workmanship that contributed to the problem.

 You can see in this second image, where the door frame broke away from the rest of the frame and the exposed hole in the top corner underneath the brickwork.

When we arrived initially to survey the project (free quote), we advised the client that the usual practise was to completely replace the door and frame.

The client inquired as to the cost and we informed them that the average cost in the St Louis region was between $1500 and $2400 depending on the selection of replacement door and frame.

The average cost for a standard external door and frame (no glass window in door) in this region, at discount hardware chains like Menards can be ~$480-$700 depending on color, style and preference. Average installation by a trained and qualified technician can be ~$800 - $1200.

 Notice the shape of the protruding cinder blocks and brickwork.

You can also see how the original door frame is constructed,

The use of round wooden splints to connect the outer part of the original frame to the other section of the frame displays the 'cheapy" construction of an average door and frame.

 This image shows the bottom portion of the brickwork and cinder blocks and the threshold.

The client did contact a few other door installers at our advice to compare costs and called us back because we were the only ones to offer a solution that did not require complete door and frame replacement.

Our cost effective solution was to provide a single piece of hardwood 4x4, custom shaped onsite to the shape of the brickwork and cinder blocks, enabling complete coverage of the exposed cavity.

Because the house was still settling and the foundations shifting (after 50+ years since original construction), the door cavity was crooked and we were required to carefully carve the inside of the hardwood piece to accurately fit around the different protruding bricks and cinder blocks. We used our orbital saw, our power file and hand chisels to expertly carve the inside of the new piece to the required shape of the fitting.

We then attached the outer piece to the inner existing frame with 4" countersunk wood screws and embedded them deeper into the new hardwood single piece, so we could fill the holes after and provide a satisfactory look.

We made sure to have enough length to shape around the threshold too, but the shape of the brickwork still revealed a significantly different size gap at the bottom from the top.

The finished result is not perfect, but significantly improved from before and much longer lasting.

Way more competitively priced than complete door and frame replacement, the total end cost to the client was $870 including all parts and labor.

We caulked around the top and sides of the new trim and frame with water-resistant Silicone caulk (to protect from future wet weathering).

We suggested the client to paint the frame themselves at their convenience (as we are not professional painters). 

An interesting yet time consuming repair, that saved the client a lot of money and looks and operates great,

Remembering back to the beginning of this post, where we mentioned about poor workmanship often being a cause of future issues......

"if you only want to pay peanuts, expect to get monkeys"

and

"the pain of poor quality lasts long after the pleasure of cheap price is obtained"