Step 1: Remove Existing Hardware (If Retrofit)
If replacing existing butt hinges with a continuous hinge, begin by removing the door from the frame. Remove all existing butt hinges from both the door and the hinge jamb. Fill any existing hinge mortise pockets with filler plates if the continuous hinge leaf does not fully cover them. For new installations on doors without existing hinge prep, skip to Step 2.
Step 2: Verify the Strike Location
Before installing the continuous hinge, confirm that the strike location on the strike jamb aligns with the latch on the door. When using a surface mounted continuous hinge with an in-stock door and an existing frame, the strike cutout position may not match the latch location. If the strike does not align, the strike plate must be relocated or the strike cutout must be modified before proceeding with hinge installation.
Measure from the bottom of the frame to the center of the existing strike cutout, and compare this measurement to the latch location on the door. Any discrepancy must be resolved before mounting the hinge.
Step 3: Position the Continuous Hinge on the Door
Lay the door on a flat work surface with the hinge edge facing up. Position the continuous hinge along the hinge edge of the door with one leaf flat against the face of the door.
• Align the top of the hinge with the top of the door. The hinge should run the full height of the door. For an 83-inch hinge on an 84-inch door, the hinge will have approximately 1/2 inch of clearance at the top and bottom.
• Center the hinge leaf on the door edge so that the hinge barrel sits at the pivot point where the door meets the frame.
• Use clamps to hold the hinge securely in position while marking screw locations.
Step 4: Mark and Drill the Door-Side Screw Holes
With the hinge clamped in position on the door, use a center punch to mark each screw hole location through the hinge leaf onto the door face. Remove the hinge and drill pilot holes at each marked location. For hollow metal doors, use a drill bit sized appropriately for the screw type (machine screws or self-tapping screws). If the hinge has pre-punched holes and uses self-tapping screws, pilot holes may not be required on steel doors.
Step 5: Fasten the Hinge to the Door
Reposition the hinge on the door, aligning the hinge holes with the drilled pilot holes. Install screws starting at the center of the hinge and working outward toward the top and bottom. This sequence prevents the hinge from shifting during fastening. Tighten all screws securely but do not overtorque, as this can strip the holes in hollow metal doors.
Step 6: Hang the Door in the Frame
With the hinge attached to the door, position the door in the frame opening. The free leaf of the continuous hinge should rest flat against the face of the hinge jamb.
• Support the door at the correct height using shims under the bottom edge. The standard gap between the bottom of the door and the floor is 3/4 inch for commercial applications.
• Verify that the hinge barrel is aligned vertically along the edge where the door meets the frame. Use the level to check plumb.
• Clamp the free hinge leaf to the frame to hold the door in position.
Step 7: Mark and Drill the Frame-Side Screw Holes
With the door shimmed and clamped in position, mark the screw hole locations on the frame through the free hinge leaf. Remove the door and drill pilot holes at each marked location. For hollow metal frames, ensure the drill bit and screw type are compatible with the frame gauge.
Step 8: Fasten the Hinge to the Frame
Rehang the door and align the frame-side hinge leaf with the drilled pilot holes. Install screws starting at the center and working outward, following the same sequence as the door-side installation. Tighten all screws securely.
Step 9: Check Door Operation and Adjust
With all screws installed, verify the following:
• The door swings freely through its full range of motion without binding.
• The gap between the door and frame is consistent along the hinge side, head, and strike side.
• The latch engages the strike plate correctly when the door closes.
• The door does not sag or drift open or closed on its own.
If the door binds or the gaps are uneven, loosen the screws on the frame side, reposition with shims, and retighten. Minor adjustments to the frame-side leaf position can correct most alignment issues.
Step 10: Install Remaining Hardware
After confirming proper door operation with the continuous hinge, install the remaining hardware: lockset, closer, kick plate, and any additional accessories specified for the opening. Verify that all hardware functions correctly with the continuous hinge in place.
