Should we have let the contractor cut our studs for a bigger door?

You 100% made the right call here. Modifying a header by three inches isn't just "extra labor"—it’s structural surgery. If your original opening had a standard header and they need to move the height up by three inches, they'd likely have to shrink that header or move the entire top plate assembly. Shrinking a header on an exterior load-bearing wall without an engineer’s calculation is a recipe for a sagging roofline or cracked drywall within a year.

The fact that they even suggested this as a "free upgrade" is a massive red flag. They likely ordered the wrong size and were trying to avoid the cost of a non-returnable custom Pella unit. No profesional worth thier salt starts a demo before dry-fitting or at least measuring the new unit against the existing frame. Trashing your old door before realizing the new one was six inches too wide is basic negligence.

Moving studs by six inches isn't just about "ripping things out." You have to consider the **load path**. Moving king and jack studs changes how the weight of your house is distributed down to the foundation. In an older house, you also run into issues with matching exterior siding, interior trim, and potentially disturbing old electrical runs that might be tucked next to that opening. It’s never as simple as they make it sound when they’re trying to cover their own mistake. Stay firm on the wait. Six weeks of walking around the house is a minor annoyance compared to the structural headaches of an unpermitted, hack-job header modification. Make sure they’ve properly weather-sealed that plywood in the meantime. They shold be eating the cost of the new door and the temporary boarding, and frankly, I’d be watching them like a hawk when they finally return to do the install.

I’m just starting to look at replacing my front door and this thread is honestly a bit scary. I didn't even think about the warranty side of this. If they start cutting into your house just to force a door to fit, whould that void the Pella warranty? I've heard those big brands are really picky about the rough opening being exactly right. It sounds like they were just trying to avoid paying for a second door. Six weeks of walking around is a pain, but it beats having a door that leaks or won't lock becuase the wall settled weirdly. Did they at least offer a discount for the massive delay?

You definately dodged a bullet. Beyond the structural mess, think about the exterior finish. Widening an opening by six inches means cutting into your siding, brick, or stucco. Unless you have a stash of original materials, matching the color and weathering is almost impossible. You’d be looking at a permanent "patch" look around the frame that kills your curb appeal.

Also, check if these guys are even Pella Certified. A certified installer wouldn't dream of proposing a hack-job like that just to cover a mis-measurement. I’d seriously consider finding a new crew to install the correct unit when it finally arrives. Those warranties are ironclad but only if the install is by the book.

I'd be checking if your city requires a final inspection for door replacements. If you let them hack the wall and then tried to sell your house later, a savvy home inspector whould see that header mess and flag it instantly. You’d end up paying way more to fix it then than you’re 'saving' now.

Since they're the ones who messed up the measurements, are they giving you a discount for the six-week headache? I’d be pushing for a solid credit on the final bill for the massive inconvenience of having your house boarded up like a construction site.