I have installed several prehung exterior steel entry doors over the last few years, and virtually all of them have minor leaks somewhere around the bottom. The first was the entry door to our garage, which has now rotted and will need replacing this summer. Obviously, I don't want any other doors to rot like the first one, or worse yet cause structural damage to the buildings.
I've tried to follow the best building practices I can, wrapping the wall felt into the door opening, applying flashing tape around the opening (bottom, sides, then top), caulking with high quality PL polyurethane caulking, etc. The exterior door frame is completely sealed and there's no possible way water is coming in around the exterior of the frame.
As far as I can tell, the water comes in somewhere around the door sill at the bottom. I'm not positive, but I think the water runs down the sides of the door against the weatherstripping then along the crack between the metal sill and the the wood jambs. I've tried caulking these joints also, which has helped, but the water is still getting in somewhere.
Unfortunately, there's no overhanging roof to protect most of the doors, and adding an external storm door is not an option either.
I'm stumped. It shouldn't be this difficult to make a door water tight...
Any ideas?
Thanks,
Anthony