Replies

1. 
   jim_l | Jan 22, 2002 12:11am | #1

   *
   Bore holes in the corners, cut out with fine tooth sawzall, leaving 1/16". Clamp oak strips on both sides, inside and out so metal is firmly held and file to final size using a large flat file.

1. 
   p_m | Jan 22, 2002 04:38am | #2

   *I haven't run into exactly this situation, but what I would do is use my 4" Makita grinder with a metal cutting disc [1/16" thick by 4" dia.]. Actually any grinder should do. Harbor Freight has 'em for maybe $30 and the discs are available for about $3 from Home Depot, etc.Or you could cut out as above [in Jim l's post] and use the grinder with a regular grinding disc instead of the file. More faster. -Peter

1. 
   GACC_DAllas | Jan 22, 2002 06:04am | #3

   *I'd go with Jim L's suggestions. A jig saw will work if you don't have a sawzall. If you use the sawzall, press the shoe against the surface of the door or it will rattle like a big dog (excuse the analogy).The cut in the door doesn't have to be beautiful. Most of those pet doors have a flange to cover the hole.You will need the wood on the inside of the cuts to give the door some body before you tighten down the nuts on the pet door.Good luck,Ed.

1. 
   Tim_Kline | Jan 22, 2002 07:16am | #4

   *If you do use a jigsaw, you need a blade that will only cut one side of the door at a time, otherwise the blade will catch. It then binds and jumps all over the place.

1. 
   Dave_Richeson | Jan 22, 2002 10:57am | #5

   *The metal in the garden variety metal door is most likely 28 ga. or 26 ga. at best. The soild core is foam. I turn an old blade backwards on my circular saw and cut out the hole inside the line. There are also metal cutting abrasive blades for circular saws. I have use both on 22 and 24 gauge steel siding. It is a heck of a lot easier to control than any jig saw or saws all.Eye protection, hearing protection, long sleave shirt, and gloves are a must. Maybe even a face shield if you have one.Set the blade depth shallow to minimize the amount of foam you melt or gouge out. Dress up your cuts with a file or grinder.Send everyone else and the dogs for a long walk if you use a circular saw. No point in ruining your family and pet hearing while you are cutting.Dave

2. 
   Mad_Dog | Jan 22, 2002 04:33pm | #6

   *Jigsaw works well. File if you want to, but the dog door flanges cover the edges anyway...

3. 
   iron_helix | Jan 23, 2002 03:29pm | #7

   *PhilipA fine tooth carbide blade does well. Face sheild & ear protection required. Coat the freshly cut edges with primer and a finish coat(or silicone caulk coating) before installing doggy door to prevent rust streaking from any invading water........................Iron Helix

4. 
   Don_Wood_in_Brooklyn | Jan 24, 2002 03:30am | #8

   *I just installed a bunch of locksets in and trimmed the ends of those same doors. I started (trimming) with an abrasive wheel in my circ saw, but found that a good metal blade in my jigsaw, (running at 1/2 speed and with oscillation set at zero) did a much neater job just as fast. 'Bonus is you do not have to dress for 17th century battle, just eye and ear protection and common sense. Spend the seven bucks for a file to deburr the edges. Once you have it, you will use it a surprising amount of time, and once you get the hang of the angle, you really get that "Old World Craftsman" buzz.***Whoah...where I was cutting was meant to be cut and there was no styrofoam inside. That stuff, while melting, releases some very bad stuff. If you are cutting through it, you should probably be doing this job outside or with the garage door open and a fan on 'ya. Just covering the safety bases...Don

5. 
   Brian_Smith | Feb 14, 2002 09:08am | #9

   *:-)brian