How to Frame and Size Rough Doors

Choose a piece of hardwood lumber at least 80 inches long, with at least one good straight edge. Nail this board to one long edge of your door so it overhangs by 1/2 inch. Measure from the vertical rail of your door at the top and bottom to attach it in line with the door's original lines.

Set your table saw fence 1 inch wider than your intended door width. Turn the saw on and run the door through, with the hardwood riding against the fence. Remove the hardwood, adjust the fence to the desired door width and cut the other edge. Repeat the process with the top and bottom of the door, if they are out of square. Standard door height is 80 inches; cut yours to 79 inches.

Cut a piece of 1-inch thick hardwood, as wide as your door is thick and as long as your door is wide. Glue and nail this strip, with all edges flush to the bottom edge of your door, to correct the difference in height.

Cut the jamb header from the jamb kit 3/4 inch wider than your door, using a miter saw. Nail the header between the two vertical jambs, fitting the ends into the grooves, or dados in the side jambs for this purpose. Apply wood glue to the ends of the header and nail it to the side jambs, using two 16d nails in each side.

Measure 12 inches down along the hinge side of the door and place a hinge plate on the edge of the door; trace around this to indicate where the door will be mortised for the hinge. Do the same at the bottom and in the center of the door's edge. Use a chisel and hammer to cut the material from the outlines to a depth of 1/8 inch. Set the door in the jamb frame, 1/4 inch below the jamb header. Mark the positions of the hinge cutouts onto the jamb. Use the hinge plate as a template and mark and cut the jamb side mortises with a hammer and chisel.

Separate the hinges by using a hammer and large nail punch to drive the pins out. Attach a hinge half to each mortise in the door and in the jamb using 3/4-inch wood screws. Set the door onto the jamb, aligning the hinge halves. Drive the pins into the hinges with a hammer.