How To Cut A Square Hole In A Metal Door: Step By Step Process Of Cutting Square Hole In A Metal Door

Step-by-step Process Of Cutting A Square Hole In A Metal Door

If you are looking to cut a square hole in a metal door, you can do it easily yourself which will help you save a lot of time instead of calling any professional to do the job. Some of the most common home improvement projects that need altering the door include installing a window or pet door. However, you need to apply the same technique to cut the door for both projects, just in different locations. The metal skin on a door is extremely or comparatively thin by most standards. The most difficult part of the project is placing or arranging the openings in a straight line on both sides of the door correctly. In order to cut a square hole in a metal door, go through the below-mentioned step-by-step process carefully and achieve the desired result of your work:
  1. Unscrew All The Door Hinges To Remove The Door
    Place or arrange a pin punch with the bottom of the hinge pin, before tapping gently & delicately with the help of a hammer in order to remove it. Repeat this step for all the other door hinges in order to pull out the door. Then, position the door on a set of sawhorses or stable workbench.
  2. Square The Template Vertically & Horizontally
    Place a template that is exactly of the same size as the size of your cut-out on the surface of the door in the applicable location. Calculate or compute over from one side of the door in order to square the template vertically. Calculate over from the bottom or top of the door in order to square the template horizontally. Draw the outline of the square template onto the door surface with the help of a pencil. Repeat the same process on the other side of the door.
  3. Protect The Door's Finish When You Cut
    Prepare the jigsaw by placing, fitting, or pushing a metal cutting blade. Put or place the jigsaw base to a depth that keeps away the blade from hitting the other side of the door when cutting. Apply masking tape to the underside of the jigsaw base in order to protect the door's finish when cutting.
  4. Drill Four Pilot Holes Through The Door
    Equip a power drill using a 3/8-inch metal cutting drill bit, before drilling four pilot holes through the door at each inside corner of the square. Make sure not to drill all the way through the door, instead, just one side at a time.
  5. Cut Along The Line On All The Sides Of The Square
    Place, fit, or push the blade of the jigsaw in one of the pilot holes, before cutting along the line on one side of the square. Repeat the same process for the remaining sides of the square. Flip the door over, and then repeat the above-mentioned steps.
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