I have recently installed a new commercial 3'0" x 6'8" metal door into an existing metal door frame for the entry/exit from my basement through the bulkhead door. the problem being the door just "hits the metal frame on the bottom and will not close completely. it seems that "shimming" out the hinges would not work as that would push the door closer to the frame. any suggestions other then grinding the door and using some metal "body" filler?
Unfortunately, one manufacturers 3-0 may not equal that of another. By putting the replacement door in an original door frame, you are stuck with the original measurements. Sounds like the original door may have been just slightly smaller than the replacement. As you are seeing, even 1/16" can make a difference.
Your choices are to either modify the new door by grinding and repairing or getting a different door that fits the existing frame better. Also, of course, you could get a whole new pre-hung unit but that's the most expensive option in materials and time.
the exterior frame is in the concrete basement wall. so, sounds like grinding it is my only option and getting some metal filler and repaint.
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