Expert: Jamie Yocono - 11/16/2003

Question
I have a hollow core, 1 3/8" door that is about one-quarter inch too long since getting new carpet. Can you suggest how I may cut this down without fraying or splintering the luan veneer?

Answer
Hi James,

I'm assuming you have a few power tools that could help you with this task. Without knowing what those tools are, I'll talk you thru a few different techniques.

With a power circular saw, the blade cuts from the underside, so chipping occurs on the top surface. You need to try to eliminate that chipping. Some people use a layer of tape on the surface to minimize the chipping, but frankly, I've never had a great deal of success with that technique. But - if you want to try- put your door on some sawhorses, and place a long piece of tape where you intend to cut, on the top surface of the door. Then- measure and draw your line right over the tape. I would use duct tape, which grips tight, instead of masking tape. Just my preference. Using a power saw, cut the door. The tape will keep the veneer stable and less likely to chip. After cutting, GENTLY peel the tape off, and sand whatever fuzz there is from cut. I would practice this on a piece of plywood first, and make sure you orient that grain in a similar direction as the door, probably cross-grain.

The other way I would try it is with a router, a straight cutting bit, and a straight edge clamped to your door. Mark the line for the cut, clamp the straightedge to your door the appropriate distance away from your line, and then make a series of cuts (probably 1/4" deep for each cut) until the door is completely trimmed.  Having another set of hands would be helpful, especially when the scrap piece is about ready to break away. If you just let it fall, it can sometimes damage that last thread of veneer connecting the two pieces.

You could also trim the door with a jigsaw and a straight edge, since the jig saw doesn't chip that much. It would be slower, but it would work too. Depends on what tools you have.

With any of these 3 techniques, please make sure your clamps are well tightened. I'm saying that from (bad) experience.  :)

OK, I hope this help. Feel free to write back if you have any other questions.

Jamie Yocono
Wood It Is! Custom Cabinetry
Akron, OH