HELP! Bought new door. Hinge mortises don't match existing frame

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Forum topic by Dreban posted 11-02-2019 04:32 AM 1106 views 0 times favorited 6 replies Add to Favorites Watch
View Dreban's profile


63 posts in 1220 days

11-02-2019 04:32 AM

I bought a new front door for a really great price knowing that the hinge mortises did not match the ones of my current front door. Should I fill the hinge mortises of the new door with wood Bondo and Route out new ones matching my original front door, or should I fill in the hinge mortises on the door frame with wood Bondo and Route out new ones on the frame? Or is there another way of doing this. I’m not thinking of? Thanks for the help!

6 replies so far

View JerryMaldonato's profile


46 posts in 1533 days

#1 posted 11-02-2019 04:54 AM

Six of one; half a dozen of the other. I’d probably choose to fill and cut fresh mortises on the door since it’s more accessible.

View controlfreak's profile


2702 posts in 811 days

#2 posted 11-02-2019 12:26 PM

Like above the door is easier to work on and is portable to limit dust issues. You can also keep the existing in place while you sort out bondo and sanding. If the one is stained vs painted I would then opt for working the painted piece because it is easier to cover your tracks.

View LeeRoyMan's profile


2061 posts in 937 days

#3 posted 11-02-2019 01:36 PM

I would also do the door.
Chances are the mortises overlap?
If so I would cut a thin piece of wood to fill instead of the bondo.

View Axis39's profile


536 posts in 807 days

#4 posted 11-02-2019 03:33 PM

Another vote for the door. Accessibility being the #1 reason.

If any screw holes were close, I might throw some dowels in, but other than that Bondo works like a charm.

-- John F. SoCal transplant, chewer uppper of good wood

View Dreban's profile


63 posts in 1220 days

#5 posted 11-02-2019 06:56 PM

I think i agree with y’all. And the mortises do overlap a bit. Door going in is vinyl over mdf, i think. Actually, not sure how it’s made, loking at it. I’ll have to take a pic. Closer look shows wood interior with an mdf 5/8”-ish thick strip on the outside edges. Over that appears to be an 1/8” vinyl skin.

View Dreban's profile


63 posts in 1220 days

#6 posted 11-02-2019 07:09 PM

Looking into it more, its got the foam core and wood outer stiles and then, i believe, a 5/8” outer layer of fiberglass material. I think i need to ge get some different filler as all i have is wood bondo.

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