Consider the type of cut you'll be making, such as a cut-out or a cut-through. Put a metal cutting blade on your jigsaw to cut the outline. Installing the dog door frame will also be slightly different with a storm door. The wooden ‘bread’ layers of the sandwich keep the sheet metal flat and prevent the drill bit from wandering as it bores through the sheet metal. Extend blade life by keeping the saw’s speed slow. They don't use aluminum for entry doors because it's too soft. Pry the hinge pins out of the hinges with a screwdriver, then pull the door off the hinges and lay it down on a pair of saw horses or a table. Remove the door from the hinges, if applicable. Aluminum sheet metal can be cut with a variety of methods ranging from manual tools to highly advanced industrial systems. Cutting a metal transition strip only requires a few tools to complete. Making accurate cuts on aluminum rods, tubes and angles is easy with a miter saw and a blade designed to cut nonferrous metal (check the label). Installing Aluminum Weather-Stripping Around a Leaky Door. Hinges are small, metal plates that allow doors to open and close. Remove any door hardware. Crimp the ends of the groove closed with pliers to hold the sweep permanently in place. Transition strips come in various sizes and materials, with one of those materials being metal. When we moved in, the front door wouldn't open all the way; it drug the floor at about 70 degrees from full open. (Makita for the most part) For trimming, shaving and cutting thinner sheet I just run the blade dry, it's easier and less to clean up. Tips. The aluminum should be reasonably thin or the Dremel may not make a thorough division. (Notice that the … You would be better off, in my opinion, to carefully cut around jamb for flooring. Your best bet is to use a jigsaw with a fine metal blade. How to Cut a Door Threshold - PDF. We cut a ton of aluminum at work using circular saws, using non ferrous carbide tipped blades on 7 1/4" saws. A metal door sweep will need to be cut with a hacksaw. Determine the Correctness of Door Sweep Installation. How to Cut and Resize a Steel Clad Entry Door: We purchased a house in 2011. Slide the vinyl sweep back into the groove in the rail. Storm doors usually have windows so that you can still see outside after opening the main door. As most are anchored to floor by screws or tapcons (if concrete). Begin in one corner and continue around the form. Here is an easy to print full color “How To” PDF that correspond to the above video. Steel used for a door is the same as steel used in any other application. For cutting thicker sections I'll use Walter cool cut. 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