Solid bi-fold doors are a good option when you must alter a door significantly.
Installing a bi-fold door in an existing opening can be tricky if the rough opening is not the right width and height. The doors can still be installed, but modifications are necessary or the door will not operate properly. The type of door determines how much the door can be modified. More material can be cut off of a solid core door than a hollow core door, which may only have 1 inch of solid wood around the edges. Does this Spark an idea?
Instructions
1. Determine how much to cut off. For hollow-core doors, it is important not to cut too much off of one door. Some doors have a 1-inch solid rail and others a little more. Ask your door supplier if you are not sure. Leave at least 7/8 inch of solid material to keep the door structurally sound. If necessary, cut off a little from each door to keep from taking too much off of one door. For solid doors, the visual look determines how much is cut off. When a significant amount of material must be cut off, divide it between the doors to keep the rails somewhat uniform.
2. Set your table saw to the desired width and cut the door. For veneer doors, score the cut line in the direction that the blade cuts with a sharp utility knife and straight edge, such as a level. This is only necessary on the underside of the door. In many cases, cutting the height of the door with a circular saw may be more practical. Cutting the door to width is best done on a table saw to keep the cut uniform, but a circular saw can be used. Circular saws blades cut upward, so score the upside of the door.
3. Clean up the vertical edges of the door with a power hand planer to remove the saw kerfs and round all the edges with sandpaper.
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