How to Adjust For an Exterior Slab Replacement Like a Pro | Step By Step Guide

Task Category: Doors

Skill Level: 1

In the new home construction process, exterior door slabs are used to replace temporary “bang doors.” A bang door is a low-quality, temporary door installed during the construction phase to secure the home while protecting the final, finished door from the wear and tear of ongoing work. Construction activities often involve moving heavy materials, working with equipment, and exposing the area to dust and debris, all of which can easily damage a high-quality door. The bang door, therefore, serves as a protective stand-in, designed to absorb any potential damage without concern for appearance or longevity.

Once construction is nearing completion, the exterior slab door replaces the bang door. The slab door, which is typically more robust and aesthetically pleasing, is installed to provide better insulation, security, and curb appeal. This practice ensures that the finished door remains in pristine condition until the home is ready for occupancy. While the process of swapping out the doors requires precise adjustment of the exterior slab for a perfect fit, the approach offers a practical solution for maintaining the quality of new doors in an active construction site.

Tools Needed:

• Hand Tools

• Drill or Impact

Supplies:

• Shims

• 3" Screws

Materials:

• Correct door and hinges

Quality Check Criteria:

• Door operates properly

• Correct reveal around the door

• Door seals tight to weather stripping

• Door latches securely

  
  

Process for Adjusting an Exterior Door Slab

1. Preparation: Before casing the door frame of an exterior door that we did not install, make sure the new door slab (not the bang door) operates within the frame.

   
   

2. Remove Old Door and Hinges: Take off the bang door and remove the old hinges from the door frame.

   
   

3. Install New Slab: Place the new door slab with its new hinges and shut the door.

   
   

4. Adjusting for Fit:

   • If the new door does not fit well, adjust it by putting some longer screws in the top or bottom hinges to loosen the reveal, or tap in shims behind the hinges to close up the reveal.

   • If there are existing shims behind the hinges and you can’t get the door to move, dig them out. You may also need to remove any extra spray foam, insulation, or drywall that could be obstructing the door from adjusting correctly.

     
     

5. Final Adjustments: Once adjustments are made, install new shims and insulation where necessary. Make sure to check that the door seals properly on the threshold. There should be no daylight visible around any part of the door when shut.

   
   

6. Casing the Door: After ensuring proper fit and seal, case the door.