How to Cut a Hollow Metal Door

A hollow metal door is made of hard metal material with a skin layer on both sides and filled with insulation.  It is an alternative to wood doors and has become very popular in recent years because of its unique features and high thermal insulation properties, and providing strength that exceeds softwood. It’s not difficult to install, but your door can be deformed during the process, which will waste time and effort if you do it wrong. So today, I am going to discuss how to cut a hollow metal door.

Metal Door

Benefits of Using Hollow Metal Doors

  • Cheaper than solid doors: Hollow metal doors are cheaper than solid wood, aluminum, or steel doors.
  • Easy to install: Hollow metal doors make it easy for you to install them by yourself. You will not need any extra help.
  • Durable: Although a hollow metal door is more durable when compared to other materials like wood and fiberglass, your hollow door will be strong enough if you install it well. The main point here is that you have to choose a good-quality hollow metal door instead of buying cheap ones from low-quality sellers.
  • Fire resistant: Hollow metal doors are fire resistant ( Some models reached 150 minutes of fire resistance), so they can protect your goods against fire and heat, which helps you to save a lot of money.
  • Water and wind-resistant: Hollow metal doors are water and wind-resistant so that they can protect your goods against bad weather. That’s why it is used in many vehicles as car doors, for example.
  • Choosing the right color: You can choose any color you want from white, black, brown, blue, or red. It depends on you what model or color you like most or will match with your design goals.
  • Easy painting: The good news is that a hollow metal door is easy to paint if you want to change its color later on, so it means that you don’t need to worry about repainting the whole door every time you want to change its color once again.
  • Storing: You can store many things in hollow metal doors, but you must place them in the right places so that your things won’t be broken or damaged.  For example, if you install a hollow metal garage door and store some goods inside the garage itself, don’t place heavy and big things on the top of other smaller ones because it will damage your small goods when the heavy one is heavy falls. Also, make sure where to place the most important thing in the last layer, leave some space from that layer to the concrete floor; otherwise, that important stuff might break under pressure of storage above it.
  • Cooling: Hollow metal doors help cool your room during the summer season due to their good ventilation, which keeps your room cool during the summer season.
  • Durable: Hollow metal doors are durable and can protect you from bad weather like rain or even snow if installed properly.  For example, please don’t choose to install hollow metal doors at a low height because they will be damaged faster when compare to doors installed at a higher point.
Hollow Metal door

Step-Wise Guide on How to Cut a Hollow Metal Door

Safety Awareness Tips:

For safety purposes, you must wear gloves while cutting the door, and eye protection would be helpful as well. To avoid injury from any flying metal splinters, keep a fire extinguisher handy.

Measure the Door to Determine Size of Hole Required for Cutting:

When working with a hollow metal door, it is important to measure each vertical edge on either side and determine which will serve as your top and bottom lines and where you will cut based upon your measurements.

Cut Out Lines Using Metal-Cutting Saw:

Using a saw or rotary tool, carefully follow along the edges of your door to cut out the lines that have been drawn previously. You should do this slowly and deliberately to ensure that the cut is straight and clean. It can be helpful to use a metal file to taper the edge of your hole at this time since it will make for a smoother fit when you are placing the new door in place, but it would not be required.

Pre-Drill Holes for Screws:

After cutting out your lines, pre-drill holes on both sides of the newly created doorway using a drill bit that is slightly smaller than the size of your screws.

Assemble Door Installer Tool Kit:

You should assemble a tool kit before beginning any drilling or cutting project to have all necessary tools on hand as you work through each step of the process without interruption or delay. This will also help to keep you organized and focused.

Install Screws & Attach Door:

Using the screws that have been provided with your new door, screw it in place all the way around, leaving about 1/4″ of space on all sides for wiggle room as needed. It is a good idea to make sure that the door is flat against one side of your frame to provide even pressure across the entire surface when it is properly attached all around.

Fasten Wooden Frame Back Into Place Around Your New Metal Door:

In this step, you should work carefully and slowly around the edges of your hole while securing your wooden frame back into place using nails or wood screws until it feels sturdy once again. Again, make sure to use a hammer to ensure that the frame is as sturdy as possible.

Test & Enjoy:

Go ahead and test your new door on both sides after completing the installation process to make sure it opens and closes properly while paying close attention to any changes in pressure or shifting around your door frame so you can quickly adjust anything if needed. Once again, be careful when testing since there may be some debris from drilling and cutting that could leave marks on hardwood floors if not cleaned up immediately!

Cutting The Door

Precautions While Learning How to Cut a Hollow Metal Door

  • Do not use a grinder with an abrasive wheel to cut through the metal door.
  • Use only a cutting torch and replace or repair any protective shields while using it.
  • Never start your cutting torch directly on metal.
  • Always wear protective clothing, including leather gloves, boots, jeans, and thick shirts, before the job.
  • Make sure no one is in front of you when you light up your cutting torch.
  • Wear eye protection to avoid being hit by flying sparks from the torch.
  • If possible, turn off all electrical near mobile home siding and heating system for safety purposes. Turning off the main circuit breaker for greater safety.
  • Always wear protective breathing equipment for safety purposes. If possible, let the fumes out of the area by opening doors and windows.
  • Never cut through a door when it is closed.
  • Have all occupants evacuate their home before you start cutting.
  • Always use an oxygen mix to protect your lungs from contamination.
  • Keep a fire extinguisher nearby in case things get out of hand (optional).


Now that you have finished installing a new metal door be sure to enjoy the increased privacy and security in your home or business. You can also feel safe knowing that you could accomplish this project on your own by following these easy tips and guidelines for success. I hope you have obtained all the necessary information about how to cut a hollow metal door. Thank you, and have a good day.

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