Most lumber yards/stores have suppliers that can make anything to your specifications. Really if you want to spend $600 on a tiny custom window, you can (ask me how I know) But there are a lot of manufacturers - Simpson Door is a good, moderately priced wood door.

Lowes even sells a slab door in those dimensions you state, not custom - this was just one result:
http://www.lowes.com/pd_355920-11813-LO355920_0_?productId=3402940

Thank you, kats737. My issue is that I would prefer a flush style because my house is mid-century modern style.

I will check Simpson Door. I do not think it should cost $600.00 by the way, Home Depot priced it at under $300.00.

Hello homey bird,you are way over thinking this. Any handy man worth his salt can replace that door useing one available off the shelf of any retailer. Same with the "shoe",a hacksaw can quickly turn a 36" shoe into a 31.75 shoe. Now tell the truth homey,are you just wolfing us?

No I'm not. I have looked into Handyman option. It's coming out to be $1000.00 (materials and labor) -- for a $300.00 door, and therefore I am trying to DIY it. Except, DH does not have hacksaw or carpentry tools but has a basic toolbox so install a pre-fab door.

(Basically a handyman will charge $$ to come over, measure the door, order new, deliver and install for $700.00).

Besides, I have had one handyman come over and do work around other interior doors in the house and he basically managed to mess with functioning doors. :-( These are the perils of living in SF Bay Area. :-( :-(.

Number one. A hollow core door is a terrible choice for an external door.

Number two. A decent prehung(solid wood) from stock will be less expensive than a custom measured slab.

Number three. Labor for installing a door slab will be more than for installing a complete prehung door assembly. Making a slab fit the existing frame is a lot more work than switching hardware. Hinge mortises have to be located and cut. That alone will take more time than replacing with the prehung. Then the holes for the handle/latch located and cut.

Ok thanks for pointing that out. Will changing a frame with pre-hung door trigger patching and other tasks around the frame? That is an important issue. Also note that for a slab, it's currently $0 labor (coz hubby can do it). The moment you bring in a handyman in, costs shoot up plus there's no guarantee of quality.

" DH does not have hacksaw or carpentry tools but has a basic toolbox so install a pre-fab door."

Ok,if you say so but I still say you are smoking something AND blowing smoke or simply cluelss. Hanging doors isn't rocket science but requires more than the Matel tool chest DH recieved for his 5th birthday.

Klem1, there's no reason to turn this discussion into personal insults. If you have something substantial to participate then I am all ears but I do not need to hear judgement here. To recap: my question was to seek pointers regarding getting prefabricated doors of a certain dimension that would be an easy DIY. Let's remain focussed on core topic here.

How thick is the door? If your jamb is for 1 3/8" door, it is an interior frame; that limits your choices for getting a more weatherproof door slab.

Here is a 32x80 solid core exterior door slab (1 3/4" thickness) at Home Despot

http://www.homedepot.com/p/JELD-WEN-32-in-x-80-in-Woodgrain-Flush-Solid-Core-Unfinished-Hardwood-Front-Door-Slab-45605/202036049

This has the possibility of trimming for height and width, with the right tools.

Casey

I replaced a hollow core door to my garage with a prehung steel door from home depot for $120. It was 36" and sealed. The old door was coming apart and could not be closed. It was a waste of paint and glue. The new door keeps the garage much cleaner and everything is securely locked. I should have replaced it years ago when I bought the house.

Would it be possible to reframe the door opening to support a 36" door? If it is in the garage, you may be able to see most of the structure.

I have also ordered custom prehung interior doors from home depot for about $500, but I really love having the steel door to the garage since it is exposed to the elements and is less likely to expand/contract.

Somewhere in the Bay Area (I think it is SJ) is a company that will take your old door (well, you bring it to them) and use it as a template to cut knobs, hinge locations, etc. on a new door so you can do a simple replacement into the current frame. My spouse did that for a garage door once and it was perfectly adequate.

I know weathering isn't that big a deal out here (your interior door probably has been fine for over 50 years) but if you replaced the whole frame with a prehung door, it might be less easy to kick in when you're done. :)