Surplus doors are one of the best deals in the warehouse. They're new, they're in the original crate, and they got here because somebody else cancelled an order or ordered the wrong swing. That's it. They're not seconds, they're not damaged. They're overstock. And the price reflects somebody else's mistake, not yours.
But surplus is a different animal than off-the-shelf inventory. Sizing isn't guaranteed to match what you find at the orange or blue store, and you have to be the one to confirm a few details before you load it into the truck. Here's our short list, the same one we walk every customer through when they ask.
First: confirm rough-opening dimensions. The label on the crate will tell you slab size, but you want to think in terms of the opening you're framing into. A 32×80 pre-hung needs a rough opening of about 34×82-1/2. Bring a tape and check our cardboard cutout before you decide. We keep templates of every common size leaning against the door aisle for exactly this reason.
Second: figure out the swing. Right-hand vs. left-hand is the source of about 90% of return trips. Stand on the side the door opens toward you. If the knob is on your right, it's a right-hand. If you're replacing an existing door, take a phone photo of the current swing before you leave the house. We can't flip swing on a pre-hung, so you want this right the first time.
Third: inspect the casing and the bottom of the jamb. Surplus crates spend time in trucks and warehouses, and the most common cosmetic issue is a dent at the bottom of the jamb where it sat on a pallet. We mark anything visible with a yellow tag and discount it further. If you don't see a yellow tag, you can assume the door is cosmetically clean, but it's still worth a 30-second walk-around.
Fourth: check the hinge prep and the knob bore. Pre-hungs come bored for a standard 2-3/8" backset and prepped for three hinges. If you're reusing existing hinges or hardware, bring one piece with you. We've got loaner Allen keys and screwdrivers at the counter for the parking-lot trial fit.
Last: ask about the maker. Roughly 80% of our surplus doors come from Masonite, Jeld-Wen and Therma-Tru, the same brands you'll see at the big-box. We can usually pull a spec sheet. If you're matching an existing door, knowing the manufacturer is the fastest way to get the next one to fit the original casing.
