I have a 36" solid core replacement door that's a bit too wide for the existing jambs, which are already at their max width. The door is pre-routed for both hinges and the lock handle. To fix this, I'm considering shaving 1/4" off the hinge side and then re-routing for the hinges. I have the tools needed for the routing but I'm wondering what the best and most accurate method is to cut that 1/4" off the door. I own a table saw, circular saw, router, and an electric hand plane, but I don't have a jointer. Would it be worth it to invest in a track saw for this project?
5 Answers
You can clamp a straight edge to the door and rip that 1/4" off the hinge side. After that, just route the hinges back in place. If you feel like showing off with hand tools, mark the line and plane it down with the electric hand plane, but only if you're okay risking a bit more work!
You could check with a local woodworking or cabinetry shop. They might be able to run it through a jointer for a small fee, which would give you a nice smooth edge.
A table saw is a great choice too! Make sure you use a sharp 60T fine blade and tape along the cut line to minimize chipping. Just be cautious about getting proper support at both ends of the door, and maybe have a buddy help out. If you prefer to be a bit precise, you could even leave it a tad oversized and do some sanding or planing at the end.
I actually tackled a similar job with an electric hand planer. Just make sure to create a template for the hinges first, then plane down the hinge edge. After that, use a router to cut new mortises for the hinges. It can be a bit of a process, but worth it in the end! Just remember to double-check your hinge alignment afterwards.
Using a circular saw with a straight edge guide is definitely a solid way to go. You can even use a piece of plywood or another door as a guide.
That’s a great tip! I actually use a 1" square aluminum tube for my straight edge; it’s lightweight and easy to store. If you've got something on hand, even better!