When and How To Replace Bulkhead Doors

Bulkhead doors serve as an exterior entrance to your basement, providing both access and protection from the elements. When bulkhead doors show signs of wear, replace them promptly to prevent water damage and maintain your home’s structural integrity. In the video above, This Old House expert Tom Silva demonstrates the process of replacing old bulkhead doors with new, pre-primed steel ones.

Signs It’s Time To Replace Your Bulkhead Doors

Here are some telltale signs that indicate it’s time for a bulkhead door replacement:

• Doors that don’t sit squarely on their frames
• Significant rust and corrosion on steel doors
• Visible gaps between the door and frame
• Warped or rotten wood doors that no longer latch properly
• Water seepage into the basement around the bulkhead area

Don’t delay replacement once you notice these signs. Waiting too long can lead to water damage and degradation of the frame and foundation underneath, resulting in more extensive and expensive repairs. Water seepage can cause mold growth and structural damage, and pests can find their way into an unsealed basement.

Choosing the Right Material for Your New Bulkhead Doors

When selecting new bulkhead doors, consider the following materials.

Steel Doors

Steel doors are durable and long-lasting. They resist warping and are less prone to damage from fallen debris. Silva installs pre-primed steel doors, which offer excellent protection and longevity and require little maintenance. You’ll usually pay between $900 and $1,600 for a new steel bulkhead.

Wood Doors

If you prefer wood doors, opt for tongue-and-groove cypress, cedar, or mahogany. These woods are naturally resistant to decay and insects. Pressure-treated lumber is another option for wood doors. Wood doors are a little less expensive than steel at $500 to $1,500, but they require more maintenance and won’t last as long. Ensure any wood in contact with stone, mortar, or concrete is treated with a preservative to extend its lifespan. Use stainless-steel fasteners and hardware to prevent rust stains. 

Other Materials

Plastic and fiberglass bulkhead doors are also options. However, plastic doors are prone to breakage from fallen debris, while fiberglass often cracks or warps after extended sun exposure. We don’t recommend these options, and they aren’t any less expensive than wood or steel. Plastic doors retail for $1,200–$1,500, and fiberglass doors typically cost $1,000–$2,000.

Cost data in this article was sourced via Angi.

Tools and Materials for Bulkhead Doors

Before you begin, gather the following tools.

• Angle grinder with cutting wheel
• Bucket
• Caulk gun
• Circular saw
• Drill with mixing paddle
• Hammer drill
• Measuring tape
• Paintbrush
• Pry bar
• Trowel
• Utility knife
• Work gloves and safety glasses

You’ll also need these materials:

• Bulkhead doors
• Fast-setting grout
• Masonry screws
• Metal primer
• Oil-based paint
• Pressure-treated 2×10 and 2×6 lumber
• Self-adhesive membrane
• Sheet metal screws
• Silicone caulk
• Wood screws

Steps To Replace Bulkhead Doors

Replacing bulkhead doors requires mid-level carpentry skills to replace the door frame. The process won’t be within the scope of all homeowners, but with the right tools and experience, it can be a DIY job. However, we recommend having an extra pair of hands to help you move heavy door frames and hold sills in place.

Step 1: Removing the Old Doors and Frame

Begin by putting on your safety gear and cutting through the hinges of the old doors using a right-angle grinder with a cutoff wheel. Remove both doors, then grind off the screw heads from the brackets securing the bulkhead to the foundation. 

Carefully pry off the metal frame and remove the header along the top of the opening. Try not to disturb the existing flashing. You can trim it and re-use it later.

Step 2: Preparing the Foundation

Clean the exposed foundation and wet the edges down with a paintbrush to keep the concrete from leeching moisture from the new grout. Mix and apply a layer of fast-setting grout, leveling it with a trowel to create a smooth surface. Allow it to dry for an hour. 

Check for any existing damage to the foundation. Address any cracks or uneven areas to ensure the new doors fit correctly.

Step 3: Installing New Sills

Once the grout has cured, cut and install pressure-treated 2×10 sills to the top of the foundation wall along either side of the door opening. Measure them across the top and bottom of the door opening to ensure they’re parallel.

Secure the new sills to the house framing and the foundation using masonry screws. To do this, drill screw-shank clearance holes through the 2x10s, then bore pilot holes down into the concrete foundation with a hammer drill. Use a cordless drill to drive a 3-inch masonry screw into each pilot hole. 

Install a pressure-treated 2×6 sill across the bottom of the bulkhead opening, ensuring it’s at the same plane and angle as the side sills. Cut the 2x10s sills to length, flush with the bottom sill. 

Step 4: Preparing the New Frame

Set the bottom foundation plate across the bottom of the opening. Mark the foundation plate to the proper length, then cut it with the grinder. Next, use the grinder to cut the two side foundation plates to length. Spray a coat of metal primer onto the fresh-cut ends of the metal.

Remove the foundation plates and apply a self-stick membrane to the top surfaces of the pressure-treated sills to prevent galvanic corrosion between the steel and wood. Then, apply a thick bead of silicone sealant along the flashing at the top of the opening. 

Step 5: Mounting the New Frame

Slide the bulkhead’s metal header underneath the flashing, then press it down into the silicone sealant. Place the door frame on top of the foundation plates and secure it with nuts and bolts. Drill pilot holes through the foundation plates, and secure the door frame with sheet metal screws. 

Use a utility knife to trim off the excess flashing across the top of the bulkhead doors. Apply a bead of silicone sealant across the header, directly beneath the flashing. Press the flashing down into the sealant.

Step 6: Installing and Adjusting the Doors

Slide the new doors onto the hinge pins and check for proper alignment. Adjust the door frame as needed to ensure the doors close squarely. Once you’re satisfied with the fit, finish securing the door frame and attach the torsion springs to the inside of each door.

Step 7: Sealing and Painting

Apply silicone sealant around the inside and outside perimeter of each door. Leave the bottom of the foundation plate unsealed to allow any water that happens to get in to drain out. 

Spray primer onto exposed screw heads and apply a coat of exterior-grade oil-based paint to protect the new installation. Regular painting helps maintain the doors and prevents rust and corrosion.

Maintenance Tips for Bulkhead Doors

Regular maintenance of bulkhead doors ensures they remain functional and last longer. This includes cleaning, lubricating hinges, inspecting for damage, and applying protective coatings as needed.

To extend the life of your bulkhead doors, regularly clean the doors and surrounding area to prevent debris buildup. Regularly inspect the doors for signs of wear or damage, particularly before and after winter. If needed, replace weatherstripping to maintain a tight seal, and touch up paint or stain to protect the material. Have the doors professionally inspected from time to time. We also recommend lubricating the hinges and other moving parts annually.

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