Replies

1. 
   saschafer | Feb 10, 2008 07:35pm | #1

   You need a metal-cutting blade. I can't say for sure without looking at the door, but probably 18-24 teeth per inch would be best.

   A bandsaw made for cutting wood usually goes too fast for steel. If you have a way to reduce the speed, it will probably work much better. Otherwise, you're likely to burn up the blade very quickly.

   -Steve

    

2. 
   RickL | Feb 10, 2008 08:34pm | #2

   A wood bandsaw is much too fast for steel. A hand held jigsaw is your best bet. Woodbandsaw are typically 3000 fpm and metal cutting bandsaws are in the 300 fpm range to cut steel. The polyurethane will melt from high speed cutting and the BS blade at high speed will dull in seconds.

1. 
   lgaudre | Feb 10, 2008 10:12pm | #3

   Thank!

   What do you think if i use a table saw with a zip cut on it?

    

1. 
   JohnWW | Feb 10, 2008 11:49pm | #4

   Lots of sparks, some smoke, and melted plastic. Should be done outdoors well away from anything that will catch fire. Best approach with a table saw would be to set the blade low and just cut through the metal faces one at a time, using a full size abrasive blade, then slice the foam core with a throw away handsaw.John White

3. 
   RickL | Feb 11, 2008 03:46pm | #5

   I rarely use abrasive blades with the new steel cutting blades out.  Pretty much no sparks and won't melt the paint or foam like an abrasive blade. Actually not all that new, probably 15 year old technology but woodworkers  do not embrace new technology that easily. Milwaukee, Makita, Jancy and many others produce such blades. I saw the Jancy demonstrated 15 years ago. Salesman cut a piece of 1/2 cold rolled plate steel with what was basically a 7-1/4" circular saw that ran at 3600 rpm and cut a strip off the plate with  virtually no sparks. Very impressive.

   http://www.evolutiononlineshop.com/Evolution_Rage/Evolution_Rage/Replacement_Saw_Blades~x.cfm

   http://www.evolutiononlineshop.com/Evolution_Rage/Evolution_Rage/Evolution_Rage_Saws/Evolution_Rage_Saw.cfm

   
   

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   Edited 2/11/2008 10:39 am ET by RickL

4. 
   dude | Feb 12, 2008 10:34am | #6

   i cut them on jobsites to install a window using a 7 1/4 blade  40 tooth on the skill saw but wear safety glasses

5. 
   doorboy | Feb 12, 2008 05:56pm | #7

   A local machine shop should be able to do it for you. It's probably less than you think it would be.

   "How do you spell illiterate?"