Door and windows

This page covers the doors and windows required to be replaced or installed as part of the extension build.

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The door between the existing house and the new garage needed to be removed in order that the back wall of the garage could be continued into the existing house, so this became the first door to be done.

It was not possible to re-use the one that came out of the gap as the new wall had a 30mm wider cavity than the old one so the opening was now too small for it to fit. (it will be re-used at the back of the garage though).

First job was to clear the opening down to the foundation, as seen in the picture.

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I forgot to take any intermediate pictures so this next one is of the (almost) finished article.

Having cleared down to the foundation I positioned the excess membrane from the garage floor into the gap then laid two courses of bricks at the bottom of the doorway. Building regulations say the door opening has to be 100mm higher than the garage floor if it doesn't slope away from the door to the outside, which mine doesn't as we laid the garage slab flat.

The floor on the other side of the door also needed to be excavated so that it could open. It will have to be a lot lower than that eventually but for now I just took off the concrete.

The door and frame are both 30 minutes fire resistant, and very heavy, so three hinges were used. The step is a bit of one of the floor joists with rebates routed out to take the base of the frame.

Still to do is to make good the gaps around the edge and stuff them with rockwool.

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The fire door is an internal grade door so I didn't really want to expose it to the elements too much.

I had a couple of sheets of OSB that I bought locally very cheap so I made a temporary cover from one of those.

This keeps the rain and sun off the door and should help protect it.

I also made another temporary door out of the other sheet of OSB to cover the gap in the wall between the existing house and the rear extension. We are a bit more secure now as we've had two open doorways for a week or so.

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The utility room door arrived and has been fitted.

This was complicated by the gap between the top half dozen courses of bricks being 10mm less than the rest of the opening and it seems that I got confused and forgot to subtract the required 10mm from the measurements when I ordered this one as it was exactly the same size as the main part of the opening and therefore didn't actually fit into the hole.

The result was that I had to trim the edge of the frame to fit it into the narrower top part and give me some fitting clearance for the rest.

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Here is what it looks like from the outside.

I had planned to recess it more into the opening than this (hence the wider than required cill hiding under the kitchen drain). I struggled to get the frame clips in and securely fixed enough to prevent the frame moving so in the end I moved it forward and fixed into the outer brickwork with hammer in frame fixings rather than use the clips to attach to the blockwork.

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The toilet window was fairly simple. With the cavity closers installed into the wall openings the frame clips were added to the sides of the frame and it was lifted into place and packed to square it up in the opening.

The frame clips were then screwed into the blockwork and then the glass panels installed.

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The kitchen window had a couple of complications. The first of which was that the opening in the blockwork was wider than that in the brickwork on one side. I resolved this by adding a piece of timber to make up the difference.

The second point was the width and the two top openers which meant it flexed when opening. This I resolved by fixing up into the lintel with some long screws which are tight in the metal of the lintel but also go into the bricks above. I only broke one screw getting the hole the right size to be a tight fit.

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You may remember from the walls page that the opening for the french doors was widened as there was a longer lintel available. I ordered a solid panel to go alongside the doors in this wider opening.

I had allowed a gap to be able to insert a piece of timber between the two and both the doors and the panel frame were screwed into this in several places to secure them together. The gap will be covered by a trim.

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The french doors were an ebay purchase so were not an exact fit for the opening. I could have added an extra course of bricks to make up this difference, but then I'd probably keep tripping over the cill so decided to make up the gap at the top.

To do this I screwed a length of 3x2 timber up into the lintel and then fixed the doors into that using some bits of soffit as packers, this will be covered by a piece of plastic trim to hide the timber.

The doors are set into the outer wall as I wanted to be able to fold them right back when open. They 'almost' go flat against the wall, I think I'll have to put a plant pot in the way to prevent stressing the hinges by going too far though.

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This is what it looks like from the outside.

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I have the final door to be fitted at the other end of the extension, however, there's more to be done before this can be put in place. This goes at the corner between the new and existing walls and the connection into the house will need to be opened up to do it.

Still to do is to add the external trim to finish the windows and doors and then foam around the gaps.

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The door at the back of the garage cannot be added yet because the temporary kitchen drain runs through it. However, there is a problem in that the rainwater builds up on the garage floor and runs down into the open wall cavity. This then flows round the bottom of the cavity and into the extension floor area though the air vents.

In order to try and stop this flooding I have added a little dam made of concrete into the door opening to hopefully stop the water running into the gap and allow the floor to dry out. This can be knocked out when the door is ready to be fitted.

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The trim has been applied to the top of the french doors to cover the gap and the timber at the top and also to cover the join between the door frame and the fixed window.

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I have also trimmed up the outside of all the windows. I used a piece of flat trim glued up under the lintel to hide that and then fixed quadrant around the top and sides of the frame.

The small gaps were filled with sealant and then the outside of the frames sealed against the walls.

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The door at the other end of the rear extension has also now been fitted.

The outer leaf of the wall has been cut away where the opening into the existing house will be created under the current window.

As you can see this (bargain) door is somewhat too short to fill the gap in the wall.

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To resolve this I made a timber frame to fill the gap and provide a base to fix the plasterboard on the inside and a cover piece which will go on the outside,

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This is what it looks like from the outside having had the cover fitted to the top (it's a piece of fascia board).

The door has also been trimmed and sealed in the same manner as the windows.

I know this is definitely toughend glass in the door as when fitting it I managed to let it fall out and held my breath as it fell to the ground. Luckily it bounced, although the frame got a bit scuffed.

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The door between the garage and main house has had the gap around it stuffed with Rockwall and the edge and top trimmed with a bit of cut down fascia and some trim.

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I thought I'd show my method for making the internal door frames so that they are a good fit for the doors.

For this I laid a door on the floor and then some pieces of timber on each corner with a second door on top of those. By using some packing spacers I then built the frame around these doors leaving the required gap all round.

With the frame screwed together the bracing pieces were screwed into place and the frame could be lifted from the jig and placed into the opening and fixed in place.

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Doors were hung and the architrave added around the door openings.

I've set the architrave back from the frame by about 5mm to give the same effect as the doors in the existing house.

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Doors and frames painted and the handles added.

I've not tapped the pins on the hinges fully home yet as I suspect I may have to give the doors a further coat of paint and its easier to drop them off and paint them flat.

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I've also finally got around to trimming the gaps around the french doors.

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This is the back door to the garage fitted into place. I just need to get a new lock as this door was originally fitted 'inside out' and the thumbturn would now be on the outside, which isn't much use from a security point of view.