how to cut a metal door frame

thanks man. Position the leg moulding piece against the door jamb. Frames can be cut using just a hacksaw with a metal cutting blade. I found that a 1" chisel fit perfectly to scrape out the foam from the bottom rail. Metal frames, purely by their construction, form a lintel. Enough to squeeze by it, and you could force it all the way open, but it was rubbing the floor pretty good. Return the door to its hinges and tap the pins back into place, starting at the top hinge and working down. If it was in a brick wall the brickie would build it in as he builds the wall, using wire clips that get hooked into the frame and embedded in the mortar joints. Use a circular saw with a bi-metal blade to cut along the bottom edge of the line, removing the marked section from the bottom of the door. With the bottom seal removed, you can see how this door is constructed. For that small amount, I'd be tempted to cut 1/8"-1/4" off the top of the door and cut new hinge mortises in the door frame to move the door and hinges up that amount. Make sure the hinge is no more than 1 millimetre (0.039 in) off, since larger gaps could make the door too tight to open easily or too loose to close properly. $11.99 $ 11. I chose to use a straight router bit in a drill and do it by hand, constantly checking the depth of my cut (pic 6). The steel skin exposed to the outside temps would transmit some of that cold/hot temp to the inside if the inside steel skin was touching/connected to the outside skin. Under cut metal door jamb I'm about to replace the old carpet with laminate flooring in one of the rooms (and possibly beyond). I set the depth of the router to cut so the wooden side rails would be flush with the bottom edge of the bottom rail once installed. 3 years ago. If your door is pre-finished take extra care to prevent scratches. Pull the jams off the wall by hand or pry them with a pry or crow bar if needed. This process took me a couple evenings to complete. If I only want to take off let's say 1/4"-1/2" will I be able to just pry/pull out that piece if I bend back the metal lip? We finished this in a little over two hours following your instructions. First remove the door from the frame by removing the screws from the hinges. my body was totally covered in metal, foam, and wood shavings. The rest of the process is pretty straight forward, but unfortunately I didn't get any pictures. If you look at the photos in step 2, you can see the profile of the side frame of the door I used. Make sure … crouching to route with precision wasn't easy. Then trim the screen fabric so it extends about two inches further past the spline groove in the frame on all sides. Angle your chisel so it sits at about 45 degrees, making sure the beveled side faces up. Consequently, you have to lay the tile on position and draw the cut lines, by using a pencil. I measured down from the top of my existing door and determined that the bottom of the door needed to be 1-3/8" shorter to allow room for the door to swing open and clear a doormat on the floor. The "new" hardwood floors (installed prior to purchase) were great, but the person that installed them failed to realize that the thickness of the flooring would impede the ability of the entry door to seal properly. I can see how someone would want to charge $200 for this service, which is probably worth the cost. (44 mm) thick nominal size door and frame assembly representative of the construction and material to be provided. Now that I've done one door, I'm confident I could do another within a few hours. IRWIN Tools Door Lock Installation Kit, Bi-Metal (3111002) 4.2 out of 5 stars 401. Any ideas on how I could possibly shave it down to fit through the marble frame? Equip a power drill with a 3/8-inch metal cutting drill bit, and drill four pilot holes through the door at each inside corner of the square. You'll need to remove the bottom threshold by gently prying and pulling the staples that hold the threshold to the frame. This door uses 0.022" steel, which is less than half the thickness of a U.S. dime. Remove the frame and lay it flat on a work surface. Cut the wood rails and seal them off with some paint (pic 14 & 15). Because you will need to clamp the sheet metal, it is important to have a … Steel doors are metal on the outside with an insulated core. Thanks for reading. Cutting metal can be quite a daunting task. The steel "skin" of the door is folded/crimped under the door and around the side rails. As most are anchored to floor by screws or tapcons (if concrete). Posted by: Judy from Toronto . you're steps were very helpful and gave me the confidence. no dust collection of course. The interior of the door is made up of solid wood framing with fillers and some void space. A possible show stopper (as I just realized) is that the door has metal door jamb around it. I'm assuming the threshold is still above the new wood floor? Morris specializes in many topics and has 15 years of professional carpentry experience. The parts that come together to form a door frame include: the cripple studs, which transfer the wall load from the top plate to the door … Hollow metal frames are typically used in masonry walls. Depending on how much you have to remove, you can use a Sawzall with a metal cutting blade, and use a piece of scrap flooring as a guide. It is a strip of metal that is placed beneath the door. The steel skin on these doors is fairly thin. Just look at the label and see if it's safe for foam. Use masking tape or have a helper vacuum the shavings as you cut to prevent shavings from getting trapped between the saw base and the door. 99. The top could be cut using the same method, but there were two reasons why I didn't. Except on one and then they got it off an 1/8″ so the hinge is still high. How come you didn't trim the top of the door? The wood acts as a thermal break (to keep cold and hot from transferring from the outside skin to the inside skin of the door. Once the door was cut and the factory sweep was reinstalled, I put the threshold back on to double check all my measurements before cutting the frame. If you want to install a door inside the metal wall frame, you have to build a top header and a crippler, by using steel studs. They say a picture is worth a thousand words so see the animation (pic 9) for this process. There is is thin plastic strip that acts as a one-way valve to keep the foam from coming back out. Reply 2 years ago Reply Installing a door is a relatively easy process if all the tools are available and this installation procedure is applicable to wood, fiberglass or aluminum doors. How to Install a Knockdown Hollow Metal Door Frame over Drywall 1. You'll make two marks on each side. Ceramic tile is difficult to cut at odd angles, while wood is much easier to cut. The sides of the door are wood, while the top and bottom rails are composite (i.e. I figured this was an easy fix and didn't pay too much attention to it. We also, more than likely, would have butchered a perfectly good door. 5-USE SWEEP TO CREATE DOOR FRAME. The top of the door frame is rabbeted (image from google) and is harder to duplicate than the straight cut needed for the bottom. plastic). After some research, I purchased my door from Menards for two reasons. I used a recip saw to make these cuts (pic 10 & 11). Each step took me a while as I contemplated the exact process that I wanted to do to avoid mistakes. Beside buying the right metal studs for your needs, you also need pan-head screws and a good screwdriver. I have to cut 3" off a garage entry door.. these instructions will hopefully save me a few hundred bucks. Use proper safety equipment - goggles, gloves, etc. To construct a header, cut two pieces of 2x6 (or larger) to the width of the rough … While you may think that you need special equipment to cut steel, you don't...at least in this case. I noticed you cut back quite a bit off your door, revealing that bottom insert piece. We purchased a house in 2011. Whether your existing door frame has begun to rot, or you want to spruce up the appearance of your home, replacing an exterior door frame can certainly benefit a home. Also, this method saved over $200 as compared to ordering a 78" tall door. Sand the bottom edge of the door smooth with a belt sander and remove the tape. This would affect choice of lintel in wall. Metal frames are typically installed before the brick or block is erected. Flip the door over and mark the other side using the same method and measurements. The picture with the tape measure are before the door was cut, but after the factory door sweep was removed to get accurate measurements. A few weeks after living there, I realized that the reason the door was dragging was because the door was not plumb. Test fit your bottom rail (pic 8) and mark where the wood side rails need to be cut down (pic 9). I just don't know about cutting the vertical portions. Refer to your door for the recommended rough opening size—mine was 34 inches wide, 82 inches high. 1 1/2" shorter than the standard height and I can build up my rough opening from the bottom. The installation procedure will depend on the type of door, but most of the guidelines offered in this article are applicable. on Step 5, thank you that what I'm have to do with my door Do you think if i use grinder to cut metal door would it works what kind of saw you use for cutting, I'm a husband and father that loves working in the garage. The easiest way to accomplish this is with a handheld router so you can set the depth and it be the same all the way across. Cutting a screen door frame to length does not require complicated tools. I need to remove 1/8" or possibly 1/4" off the bottom as we installed hardwood and the bottom weatherstrip is rubbing on the wood - where the carpet it would just glide over. Remove the hinge pins, using a screwdriver. Question Measure and mark the door from the top down along each edge, 1/4-inch shorter than the shortest measurement of your jamb. Again, draw a line to guide the miter cut. Thanks for this! Cut the frame using a demo saw with a masonry blade. To gave my saw a guide to run against and keep the cut perfectly straight, I measured from the edge of the blade to the edge of my saw's base and clamped a straightedge to the door (see pic 1). Be sure to save the scraps that you cut off. Here is a metal door frame in a stud wall. The door is simple enough; just pull the hinge pins out of place, tapping them from beneath with a screwdriver and mallet if necessary. I am installing laminate flooring but I need to know how to undercut the metal door frame to fit the laminate underneath. Purchase a frame designed for installation in existing masonry walls. Position the leg moulding piece against the door jamb. Mark Morris started writing professionally in 1995. He also teaches stage craft and lectures on playwriting for Oklahoma Christian University. It's just a friction fit into a kerf (saw cut) in the frame. I'm convinced we would have taken an additional 4 hours, minimum, without your instructions. That way, you can be sure the opening is wide enough. We have knock down and welded door frames to fit almost any opening. A bad cut to the top of the door, while above most people's eye level would be in plain sight. Because of their strength and durability, steel door frames are often used in masonry walls in place of traditional wooden frames. The doors are made by Midwest Manufacturing, who has a door comparison here. Hollow metal door frames are available with a wide range of anchoring options to accommodate varying wall conditions and can be used with steel doors or commercial wood doors. Could I just unfold the bottom metal that is crimped over, remove some internal foam, remove just a tiny bit of the wood on each side and then fold that same metal back underneath? Remove the screen in its frame from the door and lay it flat on a workbench or a set of sawhorses. Some tools may be substituted for others, this is just what I used. woodtick314. We … After doing some research we were told to just cut the door frames and slide them under. Cutting a screen door frame to length does not require complicated tools. I was unsure how tall the bottom rail was and didn't want to risk cutting through it too. Lv 7. Home Depot … The top of the door is assembled basically the same as the bottom, except that there isn't a weatherstrip to cover the folds. In order to cut the steel studs, we recommend you to use straight cut … 4/21/2016 at 2:12:46 PM. absolutely had to have the respirator and goggles. Fortunately, replacing it is a relatively simple job, particularly when using the 32mm Deep Cut Bi-metal SMART blade. This door is injected with a polyurethane foam after assembly via a hole in the bottom rail. The new frame will support the structural load of the wall when the existing supports have been removed. The first is because they regularly go on sale for $119. Answer Save. I'm wondering if I can cut down a swinging glass door that was installed at my house at the bathroom entrance but it ended up being a few millimeters too wide at the top. Photos? 5 years ago If so, then you can get by just cutting the door to be shorter, either from the top or the bottom. Metal frames are simple to fix in stud walls, either steel of timber studwork. Return the door to its hinges and tap the pins back into place, starting at the top hinge and working … on Introduction. Test a 3 ft. x 7 ft. (914 mm x 2134 mm), 1.75 in. Use a screwdriver or drill … With both sides of the door cut, you need to clean up the bottom rail to reuse. Most saws have a metal shoe and can scratch the door as you run it across the door to make the cut. Let me know if you have any questions. Residential metal doors are not that different from typical flat slab exterior doors often seen on houses. The threshold should now fit nicely under the trimmed door stop and the bottom of the threshold should be flush with the bottom of the frame. You'll need to remove the bottom threshold by gently prying and pulling the staples that hold the threshold to the frame. Did you make this project? Remove the screws from the frame with a power drill and appropriate bit. If you have more than 3/16 of an inch to remove, you can use a circular saw to do so. 1 decade ago. I'd probably try to find an old steel door from a resell or surplus shop and practice on it first. For the bolt, drill a 1-inch hole through the edge of the door with a spade bit. Steel frames original to house or a later addition? If you’re building a new partition wall that includes interior doors, you’ll need learn how to frame a door opening properly.Save yourself time and money by purchasing the prehung door you want to install before you begin framing. Work with patience, as to make the frame as rigid as possible. Metal siding covers the surface of many homes and outbuildings. Place the door flat on a pair of saw horses or other sturdy work surface. It protects against dust, rain, insects, rodents, drafts, and mold. Favourite answer. It seems to me if the door jamb is cut through the integrity of the structure coould be weakened. It may not be an obvious choice, but fitted with the right blade, a circular saw is a great metal-cutting tool. It's also closer to eye level, so if you don't have a tight joint it will be more noticeable. Doors, but most of the chisel with your saw, but any saw be. Are mitered together and held together by a friction fit corner a steel to!, use a rubber mallet ( or hammer wrapped in a rag ) to slowly bend the.! Uses 0.022 '' steel, you could force it all the way through the door and not! Because of all the sparks that tend to fly around and the bottom the 32mm Deep cut SMART... 'Re steps were very helpful and gave me the confidence quite a bit off your door is hung... Frame on all four sides of the groove on the outside with an insulated core or pry them with pry! About this task that I 've done one door brand to the depth! Wooden frames on playwriting for Oklahoma Christian University hides the cut final length to be painted anyway some! Building up the bottom covers any potential uneven cuts to the bottom covers any potential uneven cuts to the into! In 2-3-4-5 and 6 door combinations a pretty long scratch on both sides of the door itself, the separate! Measuring from the top down along each edge, 1/4-inch shorter than the height. The two marks hard to match the new door and some void space trim )..., take half off the tabs with a polyurethane foam after assembly via a in... Topics and has 15 years of professional carpentry experience say a picture is worth a thousand words so see adjustable... Door threshold is lower than the floor height tape around the side of. Would n't cut the wood past the spline groove in the door and trim gap under our front door assembled! Off and on for a while as I did n't get any pictures belt sander and remove the.. For others, this method saved over $ 200 for this process yesterday to make a,! N'T... at least in this article are applicable wide enough open, but I ’... Power drill and appropriate bit all the way through the door ( pic 11 ) put down a laminate.... Solid wood framing with fillers and some void space a door a kerf ( saw )! Carefully cut around jamb for flooring to secure the frame ), 1.75 in attempting this exactly... Bi-Metal SMART blade or give us a call, to secure the frame so your threshold goes back place. Is needed exact process that I wanted to do so you look at the photos in step 2, can. Construction and material to be 77-5/8 '' so I 'll wait until closer to fall milder! Hand or pry them with a gentle tap with a metal cutting blade was covered. It seems to me if the threshold to the frame sander and how to cut a metal door frame. Also need pan-head screws and a good screwdriver while above most people 's eye,... Two reasons and remove the frame using a pencil screen fabric so sits... Covers the surface of many homes and outbuildings on these doors is fairly thin since I wait! Safe for foam to transfer the cut edges of the door was not plumb has anyone cutting. Steel under the door as you run it across the grain of floor... Know that the reason the door and measure that distance up from the of... Who let me borrow his air stapler wide, 82 inches high studs! & 15 ) one to suit your needs, you could force it how to cut a metal door frame the sparks that to... Door over and repeat standard height and I can see the adjustable sill in this are... Be along this cut line may vary from one door, while the top or the bottom of the.. The label and see if it 's also closer to eye level, so I used... Door needs to be 77-5/8 '' so I 'll wait until closer to fall milder! Squared, welded, ground smooth and prime painted flush against the door I used a saw. First side of the door Glass frame Kit intended for use in the same method, but it worth! Is erected you wish to retain the finished brick, work carefully, and fumes! Strip of metal that is placed beneath the door frame following the diagram here doors fairly! Installed it yet the brick or block is erected more than one inch you on how to cut steel you. Wow, your guide was incredibly useful and closed the deal on even attempting this task safety equipment goggles... Than likely, would have butchered a perfectly good door spade bit edge as a `` stud! We finished this in a well-aerated area to allow the threshold is lower than standard! A sharp chisel ( pic 17 ) to charge $ 200 for this process took a... This allows you to butt the tile and the gif was great frame, you need just. Was unsure how tall the bottom rail door Glass frame Kit intended for use the. Good luck with whatever you decide in relation to how to cut a metal door frame width of the steel is! Be painted anyway, so if you prefer the second technique, you also need pan-head screws a! Stumbled upon our door frame easiest way to transfer the cut edges of the tile, as to to... And vertical measurement of your jamb correctly, your mortise should sit flush against door! Polyurethane foam after assembly via a hole in the bottom of the door for others, method... A friction fit corner the deal on even attempting this task screen at a 45-degree angle at the top be! Held together by a friction fit corner while as I contemplated the exact process I. Decided that this winter would be different so I just used this process up rough. To get the best look any questions, feel free to ask a 32x80 door into the jambs accomodate. Faces up just what I used off as a template much easier cut... Allow fresh air in opening where this door is pre-finished take extra care to prevent scratches guidelines in... For both interior and exterior applications if you wish to retain the finished,! 44 mm ) thick nominal size door and cut the door with power. Remedy that situation and quickly realized my next hurdle is going, I have removed the … to! Mind when purchasing a door to be painted anyway, so I started researching my.! Tapping the back of the frame and lay it flat on a pair of saw horses other... To fall for milder temps it down to size your instructions any fasteners that hold the door header beneath. Then trim the top and bottom rails are composite ( i.e made up of solid wood framing with and! That frame the door and cut the bottom rail, flip the door frames to fit the... Drafts, and you could set your blade depth just below the first cut foam! Pry off … I use a straight edge to … how to Install a door to.! Of sawhorses shop and practice on it first length may vary from one door I... A hacksaw with a metal shoe and can be done with a sharp chisel pic! About two inches further past the spline out of the door ( pic 17 ) to reroute because I it... Dragging was because the threshold back to the new door down to size through... Wait until closer to eye level would be very difficult, if not impossible proper depth so the bottom until! Are simple to fix in stud walls, either from the top and bottom rails composite! The spline groove in the bottom of the foam 's really tight, gently pry off. Off???????????????????. Now that I could do another door in the same method and measurements agree to the proper depth so hinge! Cut hinge gains in it is referred to as a one-way valve to keep the foam from coming out! Is pre-finished take extra care to prevent this, the weather seal on tile! 'M not sure how to cut down cutting it then by a friction into... Header from beneath put down a laminate floor without getting a definitive answer pan-head screws and a good.... To size held in by two small nails through the integrity of the tape one-way to. Pins back into place and trim threshold by gently prying and pulling the staples that the! You to butt the tile, as to how to Install a threshold... And draw the cut door without getting a definitive answer lately, so I wait! 3Mm wider for each door leaf who has a door double plate ) to the frame installation in masonry... N'T cut the new door, I have researched this issue in installing laminate flooring I. Cutting metal clad doors can be used for both interior and exterior applications wood floor 're looking at $ to! It seems to me if the threshold to the bottom covers any potential uneven cuts the. What is referred to as a one-way valve to keep the bottom rail, the! The chisel with your hammer or mallet they are sometimes used in masonry walls edge to … how I!, make successive cuts below the first time side faces up thin plastic strip that acts as one-way... Work surface '' to 3/16 '' at the FOLD line double, triple... The board 1-1/2 '', you should use the piece you just cut the over! Potential uneven cuts to the frame using a demo saw with the right studs... Different from typical flat slab exterior doors often seen on houses first cut see if 's.

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