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:

It’s important to be safe when cutting the door by wearing gloves and eye protection. A fire extinguisher should be nearby in case any metal splinters fly off and cause injury.

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. This will ensure that your door is the correct size and will fit properly.

Cut Out Lines Using Metal-Cutting Saw:

Cut along the lines you’ve drawn on your door with a saw or rotary tool. Go slowly and carefully to make sure the cut is straight and clean. Taper the edge of the hole with a metal file if you want a smoother fit when you put the new door in, but it’s not necessary.

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:

A tool kit is a collection of tools that you will need for a project. It is important to have all of the tools that you need before you start a project, so that you can work through each step 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:

Screw your new door into place using the screws provided, 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.

Test & Enjoy:

After you finish installing your new door, test it out by opening and closing it on both sides. Pay close attention to any changes in pressure or movement around the door frame, so you can make any necessary adjustments. Be careful when testing, as there may be some debris from drilling and cutting that could mark up hardwood floors if not cleaned up right away.

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).
Always Wear Protective Breathing Equipment


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.

Angela Ervin

Angela Ervin

Angela is the executive editor of DIY quickly. She began her career as an interior designer before applying her strategic and creative passion to lifestyle and home. She has close to 15 years of experience in creative writing and online content strategy for housekeeping, home decorations as well as other niche efforts. She loves her job and has the privilege of working with an extraordinary team. She lives with her husband, two sons, and daughter in Petersburg. When she's not busy working she spent time with her family.

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