Need some help cutting a steel door

[mkirkpatrick]

I was given a steel door and was going to use it for a bench top, I want to cut about 4" off the side. What is the best way. I have a mason blade for my 71/4 saw. Would that work? Or I was thinking about using a 41/2 grinder with a metal cut off blade to cut the metal and them use the 7 1/2 saw with a wood blade to finish it out. Any suggestions would be great thanks.

Mike

 

[Wanna Ride]

Cutoff wheel on a 4&1/2" grinder

 

[blue dog]

When you say a steel door, are you referring to a commercial type door?
If so, when you cut the edge off the door, you are going to have to rip a piece of 2x4 or such to stuff inside the edge after you cut it off. Typically those doors have a cardboard honeycomb filler in them, just a heads up. I would use a grinder with a cut off wheel and clean it up after with 40 or 60 grit flapper wheel to finish it off. All so, if it is a fire door, they have a gypsum type material in them that can get messy when cutting them, best to do this outside as opposed to in your garage. Heavy sob's those doors are. Good luck.

 

[Wingnut65]

Grinder for the skins or Sawzall. I agree with blue dog that you will probably end up with a loose edge that will need reinforcing added back in.

 

[kbs2244]

Don't try to cut the full thickness at once.
Cut through the steel only, then turn over to cut the other side.
Then the ends.

 

[Jack Olsen]

If you take the knob and latching mechanism out, you can probably see how thick the metal is and what the rest of the door is made of.

 

[IDASHO]

You guys are making this way too difficult.

All of my work bench tops are steel door blanks. Cut to length with nothing more than my skill saw and a fresh carbide tipped framing blade.

It zips through it like butter. And all that is needed to clean up the edge is a file.

 

[tcianci]

You guys are making this way too difficult.

All of my work bench tops are steel door blanks. Cut to length with nothing more than my skill saw and a fresh carbide tipped framing blade.

It zips through it like butter. And all that is needed to clean up the edge is a file.

Amen to that! I have cut many a steel door just like that. Buy a cheap relatively fine tooth (24 teeth) carbide for your skilsaw and have at it. Just be sure to use eye and ear protection. The chips are hot as a ******* and the noise is something you will not soon forget.

 

[6768rogues]

I have cut them with a circular saw, too. I use a carbide blade on my 8 1/4 inch saw and simply cut it in one pass. Wear safety glasses and you are good to go.

 

[Falcon67]

I've cut corrugated steel with a circular saw - use an old blade and put it in the saw backwards. Zips right through. Wear ear protection - it'll be loud.

 

[70redbee]

Use the circular saw. Ear,nose and eye protection are all a must.

 

[mkirkpatrick]

I used a 4 1/2 grinder with a cut off blade on it. Worked real well. the door has a wood frame like blue dog said, but the center is dense foam. Thanks for all the input, I will post pics of the bench after it is done. Have to have someplace to mount that old craftsman vise I picked up a few weeks ago.

Thanks all,

Mike