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Old 06-13-2010, 12:26 PM   #1
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cutting window opening in a door?

i have a beveled glass window for the solid, steel clad, walkin garage door. going to cut a 23x37" hole in door for window. i have one chance to get this right, or door is history, so i don't want to bunge it up. what saw & blade would work best to get a neat square hole cut in for this? i think a saber saw might not cut straight or square. a skill saw, with a guide?

ideas welcome.


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Old 06-13-2010, 12:53 PM   #2
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A skill saw with a steel cutting blade might work--it will depend on the core of the door--

A steel cutting blade is just a steel disk with a few heat relief slits cut into it(Menards has them in our area)--I've cut lots of steel up to 1/8 inch thick with a SkillSaw and a blade like that--An all steel(no carbide) fine toothed plywood blade also works.--Start slow and wait for the sparks--they don't really "cut' they melt the steel.

An angle grinder with a cut off wheel will also do the trick.

A set of sheet metal three blade shears (this removes a 1/8 inch strip) will work ,if the core of the door doesn't get in the way.

There are other ways,too. Some a bit dangerous--I'll leave those out.---Mike---


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Old 06-13-2010, 01:03 PM   #3
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Is this a door from the house to the garage ?
Or from the garage to outside ?
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Old 06-13-2010, 08:04 PM   #4
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The 'metal cutting' blade will overheat the metal and blister the paint. Don't ask me how I know this...

I would use a carbide toothed framing blade installed backwards (with safety glasses) to cut the hole. It has worked for me in the past.
Short of cutting off a body part, the worst that can happen in woodworking is manufacturing really nice looking kindling. --- Quoted from lenaitch
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