Is it best to return and exchange a prehung door with a gap issue caused by a poorly installed hinge, or attempt to fix it first?
Asked by Hanna Chambers 
8 months ago
Last Updated: April 30, 2024
Hey there! So, I’m dealing with a bit of a gap problem with this prehung door I got and put in. I made sure it was all straight and level, but there’s this gap at the top on the side with the handle. It seems like the hinge wasn’t put in right at the factory because it’s not lining up with the bracket slot. Do you think there’s a way to fix this, or would it be better to just return it and get a new one before I mess with it too much? Home Depot mentioned I could exchange it if needed. Any advice would be great, thanks!
Having gaps is typical and that’s why door casing exists. As for the hinge, a wood chisel can easily fix it.
Carve it out. Prior to removing the hinge, make small cuts in the wood with a knife.
If you remove it, you should be able to fit it in. They are usually a tight fit, unless they have pinched the steel trim too much. In that case, I would suggest returning it and buying a second one first so you can easily swap the door out.
It appears to be a Feather River door from Home Depot. Honestly, most Feather River doors have the same issue. The fiber material they use causes the door to expand and contract more than other brands I have installed. I would recommend returning it and getting your money back. THERMAL TRU makes some good doors that you can find at lumber yards and Lowe’s.
Fill in the gaps with expanding foam and then cover it with casing. As others have suggested, be sure to mark and chisel out space for the hinge.
Just trim it out.
Inspect the exterior brick Moulding on the strike side for any debris or old nails. Check to ensure that the bottom strike side is not missing the sheathing or has been affected by rot, causing it to thin.
I agree with , that’s the first thing I noticed too. After repairing the hinge, the top of the hinge side should extend out about 1/4″.
There might also be something obstructing behind the exterior brick moulding, preventing the door from closing completely flush on the strike side.
Did someone say the 80s called for their door back? Sorry, couldn’t resist!
It’s a simple fix, but I recommend returning it and investing in a higher-quality replacement as others have mentioned before.
If you’re only dealing with that one hinge, I’d suggest removing it and carefully chiseling it out. It shouldn’t be too difficult. However, keep in mind that you might have to readjust the door frame due to the crooked hinge.
If the door is perfectly flush to the sheathing, the top hinge side might need to be adjusted slightly. Keep in mind that walls are not always 100% plumb, so adjustments are normal when installing.
To adjust the hinge, start by loosening the screws on both the door and frame sides. Then, maneuver the hinge so it sits flush in the door. Begin by tightening the bottom screw followed by the rest. This should properly seat the hinge.