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I screwed up when ordering new door slabs. Measured everything except the thickness, and, of course, I wasn't lucky.

Anyway, the door is pre-mortised, and it won't close because it is too thick. I am trying to figure out the best way to proceed given the fact that it is pre-mortised and with the holes for lock-sets.

Can I simply trim the door stop with a circular saw or a router? If not, what other options do I have?

Thank you.

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You can't (practically speaking) make your slabs thinner. It would be a monumental undertaking considering the nature of hollow-core doors and symmetrical mortising. You can either move the stops or get new slabs and start over.

To move the stops, slice the paint with a utility knife, then work a steel putty knife behind the stop to loosen it. Gently pry the stop loose. Sand, fill, and paint the jambs.

Determine whether the stops are salvageable with sanding and repainting. Reinstall using trim nails and filler, and apply a final coat of paint.

  • The door IS too thick. It was supposed to be 1-3/8 but I ordered 1-3/4's. the reason I screwed up was because the Home Depot form didn't even have the 1-3/8 option so I neglected to check. I guess they are not so rare anymore. Anyway, there are two problems with popping door stops. One is: there are no obvious nail holes or anything like that. They could be covered by multiple layers of paint but I just want to make sure the door stops aren't somehow part of the frame (my terminology may be off). – freevillage Jun 1 '16 at 14:02
  • The second one is: The door stops extend beneath the floor. I presume, the doors were installed before the hardwood. Moving the whole thing is therefore problematic. I guess I would have to cut the door stops at the floor level. – freevillage Jun 1 '16 at 14:07
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    @freevillage - oh so many problems. Use your 1-3/4" door to make a table and then go back and order the correct thickness door. It is really dumb to look for a way to kludge in a wrong thickness door. Time to bite the bullet and do it right. – Michael Karas Jun 1 '16 at 14:14
  • Ordering new doors is not an option. I said I had used a Home Depot form but I did not order the doors at Home Depot, and I ordered more than one. I agree that I have to do something with door stops. I am looking for someone to help me with the plan and the selection of the tool. – freevillage Jun 1 '16 at 14:51

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