Cutting down door slabs - Woodworking Talk - Woodworkers Forum
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post #1 of 9 Old 03-16-2018, 09:45 AM Thread Starter
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Cutting down door slabs

Iím replacing 7 doors in my home and ordered generic sized door slabs which can be cut down to fit. My doors frames are slightly smaller than standard. Roughly 1/2Ē smaller.

Would you guys recommend using a table saw? I have a ryobi 10Ē table saw. What type of blade would work best?


Thanks


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post #2 of 9 Old 03-16-2018, 09:56 AM
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I'm not sure if the overall size of the ryobi is up to the task of cutting a door. If that is true it would be easier to use a straight edge and cut the door with a hand held circular saw.

When cutting a door to width I cut the door on a three degree angle on both sides. Sometimes if the door opening isn't square with the wall the door will bind where you have to push it closed. The angle on the hinge side will help if this happens. Then the lock side of the door needs the angle so the corner of the door doesn't hit the jamb when closing. At a 90 degree angle you would have to make the door a lot smaller than the opening to prevent this.
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post #3 of 9 Old 03-27-2018, 07:07 AM Thread Starter
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Quote:
Originally Posted by Steve Neul;
I'm not sure if the overall size of the ryobi is up to the task of cutting a door. If that is true it would be easier to use a straight edge and cut the door with a hand held circular saw.

When cutting a door to width I cut the door on a three degree angle on both sides. Sometimes if the door opening isn't square with the wall the door will bind where you have to push it closed. The angle on the hinge side will help if this happens. Then the lock side of the door needs the angle so the corner of the door doesn't hit the jamb when closing. At a 90 degree angle you would have to make the door a lot smaller than the opening to prevent this.

Steve Iím going to take your suggestion on cutting the door with my circular saw. What type of blade do you recommend to get a nice clean cut?

Thanks



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post #4 of 9 Old 03-27-2018, 07:22 AM
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Originally Posted by branimal View Post
Steve Iím going to take your suggestion on cutting the door with my circular saw. What type of blade do you recommend to get a nice clean cut?

Thanks



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Use any plywood blade. The cut should be as smooth as you can because you end up having to sand the saw marks off.
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post #5 of 9 Old 03-29-2018, 02:25 PM Thread Starter
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Cutting down door slabs

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Originally Posted by Steve Neul;
Use any plywood blade. The cut should be as smooth as you can because you end up having to sand the saw marks off.

Picked up a plywood blade. I made a jig to adjust the the heights of the door slabs.

Should I look to build something similar for the length? Iíll need to buy a sheet of plywood.

Thx



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post #6 of 9 Old 03-29-2018, 06:31 PM
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Picked up a plywood blade. I made a jig to adjust the the heights of the door slabs.

Should I look to build something similar for the length? Iíll need to buy a sheet of plywood.

Thx



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I don't think you need all that. If you have a straight 1x6 just clamp it to the door. All you need is something to run the base of the saw against. It could even be a scrap of plywood if you have a piece as long as the door.
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post #7 of 9 Old 04-17-2018, 10:28 AM Thread Starter
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Iíve been trying to cut the bottoms off these 1 3/4Ē doors with a circular saw and a 100T plywood blade and a straight edge for a fence. I taped the doors. Iím encountering the following problems:
* Circ saw is riding up out of the cut groove and then it tilts slightly and the cut gets off track. Uneven bottom - peaks and valleys- by 1/8" -3/16Ē.
* Circ saw is smoking hot and is choking halfway through the cut.
* I switched to the stock 18T general purpose blade to cut an old door as a test and itís still struggling.
* I have a $110 Dewalt - is it underpowered for this job or am I a terrible circ saw operator

Fortunately none of the new doors were harmed (yet). I was doing test cuts on the old doors and cut off less than I needed on one of the new doors.


Any suggestions on corrections I can make?



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post #8 of 9 Old 04-17-2018, 12:35 PM
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Try making the cut in 3/4Ē depth increments (3 passes).
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If you don't have time to do it right the first time, when will you have time to do it over?
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post #9 of 9 Old 04-17-2018, 12:43 PM
where's my table saw?
 
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I can't know about your technique

I do know how I would make those cuts. First, use a straight edge clamp or clamp a straight edge away from the cut the amount the saw base requires, usually 1 1/2" unless the saw is reversed like this:

https://www.ebay.com/itm/E-Emerson-T...IAAOSwSzRZVJfP



I would use a 40 tooth carbide tipped blade, about 10$ at Home Depot. I would make a 1/2 depth cut to eliminate drift during the cut and make it easier on the saw motor. That will work just fine.
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The answer to your question will only be as detailed and specific as the question is detailed and specific. Good questions also include a sketch or a photo that illustrates your issue. (:< D)
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