I am the process of rebuilding a door, a previous owner had made a "cat door", but also, the hinge needed to be replaced. I will be putting new skin on the door.
I have found aluminum with a matching embossed pattern, but I measured the original at about 0.032 inches thick, what I found is 0.025, I am a little concerned that the thickness of a flange around the edge of the door that holds weather stripping will be a bit thinner by about 0.020. Will this be an issue?
The wood frame appears to be from pine, perhaps to keep it light weight or save on cost, I think only a few pieces need to be replaced, glue the joints and add kreg screws?
There is a steel rod that runs the length of the door and could be adjusted from the bottom, this appears to allow the door to be bowed ( there are 2 perpendicular saw cuts that allow the board to bend) and I measured about a 1/2 inch of outward curve, was this to insure a tight fit when the door was closed? I saw at least one post that indicated they left the rod out during rebuild.
Should I replace this piece with an unbowed and then use the rod to re-adjust the door when I put it back in?
Should I install the complete door, hinge and door frame as a unit, or can I attach the door to the frame after the frame is re-installed?
Rebuild the frame (yes, glue and screw) and insulate with rigid foam. I would leave the adjustment rod since the designed seemed to think it was necessary. It won't hurt, that's for sure. Be sure to frame for the door knob; it will need a lot of support.
I also don't think the metal thickness will be too concerning. You might use wider seals on the closing side to make up for a little more clearance. Truck camper seal comes to mind; it's about 1 1/2" wide and collapses down to allow for bumps, etc.