TS55 Cutting a Steel Clad Door

[bigGaloot]

Well, I did not want to do it, but the framing above the door was bowed down a full inch in the 200 year old house.  My measurements before ordering the door were spot on.  The custom door was NOT going to fit. 

Replacing the old door was not an option... pulling it out had destroyed the door frame.  Using the new door "as is" was not an option.  Wasn't going to touch structure, and I physically felt ill.  Client said cut the door... so I did.

Removed the door sweep and took off an inch and a half from the bottom (extra 1/2 inch was insurance I only had to do it once).  The custom 70 inch door was now 68 1/2 and could fit.

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I used the standard blade, set the speed to 1, and cut through each side in two passes, a millimeter at a time. 

Moved the the saw quickly and did not use dust extraction.  Sparking was minimal.  I should have taken some pictures of the process, but I was in panic mode.

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I do NOT recommend it, hopefully will NOT need to do it again, but it can be done... with beautiful results... although I have not used the blade on wood since the cuts in steel.  Just figured I would share.

We still need to secure the threshold, insulate, caulk, foam, and trim, but the door is in, secured, and she can sleep soundly.

 

[leakyroof]

Aren't old houses a hoot when it comes to doors and replacing them... [crying]
Nothing standard, and always some challenges [embarassed]

 

[skids]

Wow you can actually see that sag in the picture. Too bad there wasnt' room enough to put in a new header for the door to prevent anymore sag. This certainly illustrates why we need headers and jacks at load bearing door ways.

Nice work