Re: Interior doors
Replacing a door slab isn't as easy as it looks for the exact reasons you state. Your issues are most commonly caused by alignment issues, which can be many.
My advice is to start over by double checking your work, and if necessary, fill the screw holes in the door with glue and toothpicks (allow to fully dry ) and reset the hinges.
Things to be aware of:
1 - It is important that the hinge plate be flush with the surface of the door edge.
2 - The edge of the hinge must be parallel to the face of the door.
3 - The hinges must be exactly in the same position as the old door if you want them to line up properly. Since this is nearly impossible, you do the ABSOLUTE best you can, then leave the hinge ever so slightly loose as you hang the door, then snug up the screws once you drop the pin into place.
4 - Take your time, relax, go slow, and be careful as you work. The more aware you are as you do the task at hand, the better the outcome will be. Clamp the old door blank to the new door blank and flush the top edges. This will give you the proper hinge placement for the new blank. Use a square to transfer the old hinge to the new location and use a utility knife to make the lines for pinpoint accuracy.
5 - Measure carefully and transfer any remaining markings, such as hinge backset to the new slab.
6 - Continue with your straight edge and utility knife to cut the perimeter lines to the proper depth equal to the thickness of the hinge plate.
7- Remove the excess material with a good quality, sharp chisel, again, working slow and methodical and remove ONLY as much material as is necessary to get the hinge plate to sit flush with the surface.
Those are the highlights.
I suffer from CDO ... Its like OCD, but in alphabetical order, LIKE IT SHOULD BE!!!