How do I cut a metal foam core door?
by
Li Do
+1
Currently installed is a single exterior metal foam core door with a sidelight. I bought a 2nd exterior metal foam core door (door only) that I would like to cut down to width to replace the current sidelight. The result would be a door and side having matching panels.Once I cut the 2nd door to width there will be insulation or rigid foam exposed. Any ideas how to cover the open sides so it is not exposed? We live in a rain/snow climate and would like to securely close the sides before installing the piece where the sidelight was (for extra protection from the elements seeping in).Thx All!
Related Discussions
Suggested Project Book
Here's some info that may help: https://www.instructables.com/id/How-to-cut-and-resize-a-steel-clad-entry-door/
This may be helpful https://www.instructables.com/id/How-to-cut-and-resize-a-steel-clad-entry-door/
Since you will be cutting the width of the door the links provided won't work for you. Once you cut the door you will need something to support the skins. Remove about 1 1/2" of foam insulation from between the skins. Cut a board to fit the cavity. Use construction adhesive to glue it in the cavity about 1/4" deeper than the metal skins. Then fill the 1/4" with Bondo, auto body filler. Once that has hardened sand it smooth with the door surface. Prime and paint.
I had a door business installing commercial and residential doors and the one thing we would never do is cut metal clad door like you get from home stores , from top to bottom on the sides they won't last very long even if you do like William says, by installing a wood filler and then try to make it look right, with that said if it is only going to be a non- functioning, only then can you do as William says and make it work