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I need to fit a garage door frame to a natural stone wall. The stone wall return, by it's nature, is not flat like a brick return. So my questions this;

- Do i simply pack out the frame where its doesn't meet flush and then mortar the gap to match that of the stone wall?

- Do i chisel / grind back the stone return so that it is flatter to accept the frame better, then fix and mastic?

- It's been suggested that i scribe a profile piece in ply / hardwood to fill the gap but i'd need several sections as the wall meets the frame in a number of places and i think it would look rubbish.

The gap between the stone and the frame is 3/4" in some places but also meets the frame at about a dozen points.

Thoughts, suggestions, advice gratefully accepted.

I think I would only worry about the view from the front. I would stuff paper in the front of the frame/wall gap and fill around the inside with expanding foam. I would mortar onto that at the front to get a neat finish and cut the back flush of any excess foam. You might need to temporarily cover the paper with wood wedged on to prevent the foam from pushing out. It will expand out the back more readily.

DWD

CharlieBrown99 wrote: ↑Tue Sep 12, 2023 5:08 pm
- Do i simply pack out the frame where its doesn't meet flush and then mortar the gap to match that of the stone wall?

- Do i chisel / grind back the stone return so that it is flatter to accept the frame better, then fix and mastic?

- It's been suggested that i scribe a profile piece in ply / hardwood to fill the gap but i'd need several sections as the wall meets the frame in a number of places and i think it would look rubbish.

The gap between the stone and the frame is 3/4" in some places but also meets the frame at about a dozen points.

Seen the first option done on numerous occasions. On some jobs the architect specified mastic first the pointing over the top. However , on a garage door frame vibration from opening and closing could cause the pointing to come loose.
The scibbing is probably what I'd go for. You'd only need one piece rather than several , the same length as the height of the frame. Pin the scribe so that it is parallel to the inside edge of the frame( ie where it meets the door) . Hold a small piece of timber against the stone so that it overlaps the scribe. Holding a pencil against it run it down the wall marking the scribe as you do. Cut along the pencil line with a jigsaw and fettle accordingly until it fits tightly against the stone and then fix to the face of the frame , paint and if you want run a bead of mastic down the joint.