How to Cut Bifold Doors to Length

It is sometimes necessary to cut bi-fold doors to length to accommodate carpeting or an irregular size doorway. Bi-fold doors come in several common lengths to fit most door openings. Additions to openings, such as thick carpeting, can make the openings slightly smaller than the nearest door blank length. Fortunately, bi-fold doors are usually solid wood instead of hollow, like an entry door. It is a good idea to cut bi-fold doors from the bottom to avoid an irregular cut that could interfere with the top track.

Tape measure
Sawhorses (2)
Straightedge (T-square or long metal yardstick)
Utility knife
Circular saw with cross-cutting blade
80-grit sandpaper
Sanding block

Instructions

- 1
  Measure from the top of the door opening to the floor with a tape measure. Subtract 1 inch from the total measurement. This accommodates the space necessary between the upper track and the top of the door, as well as the space necessary between the bottom of the door and the floor.
- 2
  Place the bi-fold door on a pair of sawhorses. If the hinges are on the door, lay the door out so both panels are flat on the sawhorses. If hardware is on the door, pull the bottom pivot pin out of the bottom edge of the door.
- 3
  Transfer the door opening measurement to the bi-fold door, measuring from top to bottom. Use a straightedge to mark a line across the bottom of the door.
- 4
  Flip the bi-fold door over and repeat the measuring process, marking a straight line across the bottom of the door.
- 5
  Place the edge of the straightedge on the cut line and score the veneer of the wood along the line with the utility knife. Repeat for the opposite side of the door. This scoring process helps prevent splintering when cutting the door down.
- 6
  Install a cross-cutting blade into your circular saw. Adjust the blade depth 1/8-inch more than the total door thickness. Cut along the score line with the circular saw.
- 7
  Sand the bottom edge of the door with 80-grit sandpaper and a sanding block until the edge is smooth.

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Window & Door Repair