For this project we had three major challenges we had to overcome in order to complete this project:
1. Converting a small single man door opening into a 5ft patio sliding door opening.
2. The entire opening is framed in for a single 3ft man door which now has to be converted to 5ft. We have to re-frame and support the wall in-order for everything to operate properly
3. The existing opening on the outside is all siding and the inside is drywall
1. First we had to get our measurements and make sure we have the correct opening requirements for the patio door. Once we had our measurements confirmed we began prepping the cut-in opening. We had to cut past the opening we require as we needed to install king studs on both sides of the new door and a proper header above the door for support. By doing this we prevent such issues as warping, leakage and other potential performance problems. We cut the opening using a professional grade mason saw to get a very accurate cut line. Once cut-in we framed everything as required and began preparing the sill plate. The sill plate is an extremely important as it supports the door from the bottom (base). We ran 2×10’s below to be extra careful so that the door never warps or dips in the opening like the old door we were replacing. We then installed the door into the new frame.
2. Now, we had to make sure that everything is insulated and sealed properly! We used low-expansion spray foam (polyurethane) around the entire opening to make sure everything is insulated! We do this both on the inside, the outside and in behind the jamb! There is no way that any cold air will travel around the door now. In additional the polyurethane is anti-fungal so that mold and mildew will not develop around the door either!
3. Once insulated we began the finishing work. Along the inside, we installed new drywall. We mudded, sanded and prepped the drywall so all the customer has to do is paint! And, on the outside we had the issue siding. What do we do? We are unable to get the same siding and colour tone to match. So we made sure to use wide aluminum flashing all the way around the exterior opening. It turned out beautifully because the white capping matched the new door perfectly! And, with the flashing, we ended up stepping the cap into a double bend and it gave the door a beautiful rich finish!
The customers were very thrilled with how everything turned out! The new 5ft door completely transformed the space and the access to the back yard is much better. And, because the door doesn’t swing into the home it gave them more floor space to work with on the inside and way more natural light.