Tips for Replacing an Exterior Door?
I'm new here and have a few questions about replacing an old exterior door in a circa 1950's house. By way of introduction I should say I'm very much a carpentry novice.
The old door is off a deck and gets minimal use. Its very old and being on the south side has become extremely weather beaten. When I removed it for inspection recently, I discovered it was actually a hollow interior door! I suppose the fact that it was hung with two hinges should have been a clue.
The new blank I've purchased is an exterior wood door (flush with birch finish) and weighs in at 89 pounds. I plan on installing the new door by using the old door as a template to determine where the hinge mortises should go. The old hinges are 3-1/2" tall knuckle-type with removable pins and are attached using three screws.
I've read a door of this weight needs to have 3 hinges. So I plan on replacing the two old hinges and adding a third. I know I'll have to add some material into the existing wood screw holes to keep the new #9x1 screws tight (hopefully this isn't considered a bad practice?).
My first question is ... what's the best way to install that new 3rd hinge? I assume the top & bottom hinges should be installed first and checked for fit/alignment by attaching the door. I'm guessing that after this is done, the 3rd hinge can be installed on the jamb and then the position of the center mortise on the door can be determined while the door is hanging on the top & bottom hinges.
My second question is ... I've been told its a good idea to apply a coat of epoxy resin on the top/bottom edges of the door before applying a good oil-based exterior primer. I happen to build radio-controlled sailplanes and have some West Systems 105 resin. Would this type of resin be OK?
Lastly, this is really a rookie question, but I'm wondering if its good practice to apply primer to the hinge mortises and also in the lock cutouts? This was not the case on the old door.
Thanks for any tips or ideas. Needless to say, I would really like to avoid any hinge alignment or other headaches.