Looked galvanized to me, but I'm old. Gal or not, it needs painted.

(For the Australians out there: preemptive upvote.)

That's why the original is nice and thick. Oxidized and still strong.

Might be badly/not at all insulated between the jamb and rough opening. If you can, pull one side of the casing and see if you have insulation. If not, spray foam it with low expansion foam.

Honeycomb is big

Thank you for those ideias! Unfortunately the red wires are cut off. It seems this would be something really hard to fix indeed.

My dumbass thought this was a giant cookie dough cutter. On that note, you should bake a giant-ass honeycomb-shaped cookie

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It'll just get all rusty and shitty if you do that.

I'd at least throw on a coat or two of clear coat.

1.5 ton needs 600 cfm to work properly. Assuming you have 6” flex and 4x10 or so vents that’s roughly 100 cfm per vent. This is very rule of thumbish as those number can vary a bit depending on many factors If you still have at least 6 vents remaining it should be ok but I would recommend leaving it as your still working with the same amount of sq footage. That room might suffer a bit with only one vent. You could also upsize the remaining vent to compensate.

For what it's worth, I got your joke. It was a solid A.

I was thinking that may be it but wasn't sure as I hadn't seen them like this before!

Heck yeah they're awesome! A company, maybe the pioneer of this style, called "MagSwitch" I believe makes all sorts of similar including a little keychain style one that I had for a while.

Didn’t know that was a thing but the cart was definitely my first project when learning.

Preemptive downvote.

Carpenter ants for me.

Am I missing where we're told it's gal? Looks like regular mild steel welded with gasless mig.

Yes I just replaced the weatherstrip under the door and the seal around the door is good. We just bought this house about a year ago and am finding small stuff like this the longer we live in the house. The old weatherstrip was pretty beat up and this is the main door to the backyard for people and dogs. The house didn’t have gutters either so all the water dripping off the roof fell onto the deck and splashed, I imagine under the old weatherstrip. We put gutters on, but I can tell when I replaced the weather strip that there was moisture, the underside of the door had wood in the middle and was weathered.

Thank you, I’ll try the paper trick tomorrow and report back.

hexagon is the bestagon.

Had no idea what this was. Googled it. Appears to be an old wives tale. Fumes go into the respiratory system. Milk goes into the digestive.

Based on what I can see, it looks like the door weatherstrip is good, but not sure what is going on with the casing and the wood threshold. The discoloration (especially around the fasteners) indicates moisture.

The fact that the door is mostly window, what you feel may just be heat loss and not actually air exchange.

Try taping a thin piece of tissue paper to the end of a stick. Then hold the tissue paper in various places to see if it flaps around (showing actual air movement).

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Ah ok, I was curious how you did it in what looked like a garage shop.

I had metal shop do it for me on their shear.

Safety first-ish!

It turns them on and off! Wild right?!