Cutting a hollow core door lengthwise?

37,513 Views | 12 Replies | Last: 11 yr ago by AGS749901
$3 Sack of Groceries
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I have a 32" door and the frame is about 31 11/16 " wide. Pain in the ass. I'm sure this won't be as easy as just taking a circular saw the length of the door. What can I expect?

Thanks.
aggie_wes
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To buy a new door when you're done.
PlayToWin2000
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quote:
To buy a new door when you're done.


This.
$3 Sack of Groceries
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I wish it was that easy. I'm gonna have to cut the SOB. Anybody have any experience with this? It feels like there's at least a inch, inch and half of wood there to trim before I get into the cardboard honeycomb stuff.....
GasAg90
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If I understand correctly you only need to remove about 3/8" along the length. Easy way is to trim the non-hinge side (door would be off center)- if you need it to be pretty, trim 3/16 off each length and reset the hinges. A little paint and your good to go.

Just keep your cuts straight using some sort of guide.
OlRock
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I just cut one (not lengthwise) to make a washer and dryer topper. It was really easy with circular saw. You're right about there being 1" to 1.5" blocks of wood on the borders. As long as you make the right cut it seems like you'd be in good shape. If you're nervous see if Home Depot will cut it for you.
txag2008
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I did the exact thing and it was fine. Although I did use a table saw instead of a circular saw so that will be quite a bit harder to do.

I'd cut off from both sides, but that also depends on if you also want to recut your hinge mortises.
$3 Sack of Groceries
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Thanks guys!

I've got to cut the hinge mortices anyway, haven't done that yet. I understand about it being "off center" but if I cut on the knob side it will change the backset (pre cut) depth and screw with my latch, won't it? That's why I figured I'd just take it all from the hinge side.
AggieFactor
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Is there a reason you just can't make frame wider?
Aggietaco
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Just cut the hing side. You'll be fine.

It'll be much easier if you find a friend with a table saw. Otherwise clamp a guid for the saw to the door.


JP76
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Make sure you rip it from the hinge side. You want the door 1/4 inch smaller than your door opening which will give you ~1/8 inch gap on each side. Use a circular saw with a rip guide or tack a straight edge on it with a brad nailer for a guide.
The Fife
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Assuming this door has not been drilled yet for the knob hardware...

Use a planer and trim equally from both sides. Reapply the corner bevel once you're done, then prep the door for hinges and hardware. It's pretty easy this way.
rwv2055
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Tape the edges with masking tape to keep it from splintering and use a high tooth count blade.
AGS749901
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I have done this many times. As Fife already said use an electric planer. You can purchase a guide that attaches to the planner form HD or Lowes instead of messing with a straight edge. With the guide it is a very easy job and your trim will be straight and true. You can adjust the depth of your 'cut' with the electric planner. Be sure to round off the edges after you finish planning down to size because the edges will be very sharp and can easily cut/hurt someone fingers if they ever get them caught in the door.
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