Cutting a Metal Exterior Door

The reasons for cutting a metal exterior door can be as a result of many different things. The main reason to cut a metal door is because the bottom of the door will rub on the floor due to flooring being installed at a higher level. Here is what you need to do to cut through your metal exterior door to get it to the proper level.

Step 1 - Remove the Door from the Frame

 Remove the door from the frame and set it down on a clean free surface. Pull out the hinges and pop the door off. For extra protection, you can also set your door down on a surface that has been prepared with a cloth drop cloth.

Step 2 - Brace Door with Plywood

Clamping two pieces of plywood to either side of the door before cutting will help to keep the door from being ripped apart.

Step 3 - Cut the Door

You could cut the top of the door to make it shorter but then you have to reposition the hinges to move the door up on the jamb. So, generally, the best way to cut the door to fit your space is to work with the bottom of the door first. Using a table saw with a fine blade is one method of getting your metal exterior door cut to size. If you do not have a table saw handy, you can also use a circular saw. If you use a circular saw, you may need to enlist the help of a friend.

Step 4 - Fill the Metal

Once your door has been cut, you will need to smooth the bottom of the metal door with a file. After metal has been cut, it may be sharp. After you have filed the door, run a metal grit paper over it to further smooth the surface.

Step 5 - Re-Attach Weather Stripping

Assuming you have cut the bottom of the door, you will have removed the weather stripping. Purchase a new piece of weather stripping at your local home improvement center. Attach the weather stripping to the newly cut bottom of the door. Most weather stripping has a sticky surface that easily adheres to the bottom of a metal door. If you want to get a little more involved, you can purchase a door shoe, rather than weather stripping. The shoe fits on the bottom of the door and will help to keep the door ridged and insulated.

Step 6 - Re-Attach the Door

Last, put the door back in place. Re-attach the hinges and secure completely. Test the door out and make sure it slides perfectly over the surface of your floor.

Step 7 - Clean Up

Clean up your space and remove any left over scraps of metal. Discard in your trash bin.