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Discussion Starter #1
Anyone done it?

I've cut wooden doors, metal-skinned, storm doors and whatnot, but never had occasion to try a fiberglass. Now I have a guy who thinks he wants one for an odd size.

Workable? How are they constructed internally?
 

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Normally when I have one that need cut down that is what they recommend to use. I would think it should be fairly do able for you. Think maybe a finer blade to do it.
 

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Oh, yay. I've played the Bing Crosby White Christmas dance before.

I do believe I'll try to talk him out of it.
 

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Tinstaafl:

I'd be curious to know how you've cut down a metal skinned door.

Especially how to get the little bend at the top or bottom smooth. Do you take the skin off and use a brake or what?
 

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Discussion Starter #6
Score the metal skin with a utility knife, bend it a few times until it snaps off. Then cut the wood core with a circular saw.

Don't worry about that little bend; just deburr the edge. Then install an aftermarket sweep replacement that covers that edge.

I don't really have a good answer for dealing with that edge at the top of a door; those I've done were only cut at the bottom.
 

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I cut a few of them and I use masking tape on the door to eliminate burrs and prevent any scuff marks from the shoe... Now, since I got the track saw, I have been using that it gives you a nice crisp edge without the tape, and on a bit on more expensive doors, I still like to use the tape just as a precaution.
 

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With metal doors patience...........I cut a 1/4 longer than I want, de burr and spray primer on edge, then use a router to excavate the foam so I can replug the wood into the hole.

The plug should sit 1/4" deeper than the steel. I slather more sealant in gaps and clamp a 1x on edge side of the door flush with plug depth. It prevent unwanted oil canning while I peen the edge over.

I use another piece of 1x so it bends more evenly than hammer dings
 

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Discussion Starter #9
Yeah, if you're whacking that much off it gets to be fun. Wasn't thinking about that scenario with my earlier reply.

But I still don't peen it if I can cover it with a sweep. Not much point IMO, since it's glued tight anyway plus being clamped by the sweep.
 
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