How to Cut an Opening in an External Wall Door

While many external-facing house doors are solid, there are times when you need to cut openings in them, such as when installing a pet door or a mail slot. While cutting a hole in a thick exterior door may seem intimidating, most homeowners can perform the job. The most important part of the process is creating an accurate outline for the cuts, since cutting the door too much may require replacing it.

Screwdriver
Hammer
Sawhorses
Pencil
Tape measure
Straight edge (optional)
Safety goggles
Drill
1/2-inch drill bit
Jigsaw

Instructions

- 1
  Stand inside the home and shut the door fully. Locate the hinge side of the door, and insert a thin screwdriver shaft into the bottom of one hinge. Tap the screwdriver with a hammer to slide the hinge pin up. Grasp the pin, and pull it out of the hinge, then repeat the process on the other two hinges.
- 2
  Open the door, and lift up on the sides to detach it from the jamb. Carry the door outside and set it on top of two sawhorses.
- 3
  Draw a template on the front of the door that corresponds to the size of the opening you want to cut. If you are installing a mail slot or a pet door, place them on the door surface and trace around them using a pencil. Otherwise, use a tape measure or a straight edge to draw a pencil outline of the desired opening.
- 4
  Put on safety goggles. Install a 1/2-inch-diameter bit into a power drill and create a hole through the door at each corner of the outline.
- 5
  Set the drill side, and insert the blade of a jigsaw through one of the holes. Squeeze the trigger and cut all the way around the perimeter of the pencil line until you reach the starting location. Push the center portion of the door out to reveal the opening.
- 6
  Proceed with installing the desired opening cover, such as a mail slot or pet door, and then rehang the door on the hinges.

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