As I make this "new post", I realize I'm way short of details. I'll rely on
you all to ask a lot of questions, and I'll get the details as we go.

I volunteer at a non profit agency. They have a couple doors which do not
have windows, but they would like them to have windows. Metal doors, 36
inch wide, heavy. Fitted for full mortise lock.

If the window is available separately, looks like a case of drill the
corners of the hole I need. use my electric nibbler to remove the rectangle
shaped piece of heavy sheet metal. Put the two halves of the window up, and
tighten some screws.

Anyone done this? Tips, cautions, etc?

Christopher A. Young
Learn more about Jesus
www.lds.org
..

Stormin Mormon wrote:

As I make this "new post", I realize I'm way short of details. I'll rely
on you all to ask a lot of questions, and I'll get the details as we go.

I volunteer at a non profit agency. They have a couple doors which do not
have windows, but they would like them to have windows. Metal doors, 36
inch wide, heavy. Fitted for full mortise lock.

If the window is available separately, looks like a case of drill the
corners of the hole I need. use my electric nibbler to remove the
rectangle shaped piece of heavy sheet metal. Put the two halves of the
window up, and tighten some screws.

Anyone done this? Tips, cautions, etc?
My experience with a couple metal doors is that they use the hardest
stuff imagineable. Something like a cross between safe metal and the
stuff bedframe rails are made of. REALLY hard on cutting tools. You
can drill it with Cobalt drills, but typical sawzall blades will go dull
in about an inch of cutting, I think.

Jon

Oops, that's sobering. I was thinking to try my metal nibbler from HF.
http://www.harborfreight.com/14-gaug...ear-68199.html
I'd sure hate to start the job, and be unable to finish.

Christopher A. Young
Learn more about Jesus
www.lds.org
..

"Jon Elson" wrote in message
...


Anyone done this? Tips, cautions, etc?
My experience with a couple metal doors is that they use the hardest
stuff imagineable. Something like a cross between safe metal and the
stuff bedframe rails are made of. REALLY hard on cutting tools. You
can drill it with Cobalt drills, but typical sawzall blades will go dull
in about an inch of cutting, I think.

Jon

"Stormin Mormon" fired this volley in
:

Oops, that's sobering. I was thinking to try my metal nibbler from HF.
http://www.harborfreight.com/14-gaug...ear-68199.html
I'd sure hate to start the job, and be unable to finish.

naaahhh... I've cut custom openings in steel doors many times!

I've used a fine-toothed carbide blade in a circular saw, cutting VERY
slowly to prevent the saw from yanking up a rough edge. "Ferrous metal"
cutting blades work, too, but tend to burn the foam in the door. Grit
blades work great!

I've also used a 24T metal cutting sabre saw blade (in a sabre saw, yes).
Works fine. Again, high saw speed, SLOW cutting.

It's very easy to do a good job, if you keep the rate of feed low and
very controlled -- don't let the saw pull itself into the work.

LLoyd

On Jan 26, 5:57*pm, "Stormin Mormon"
wrote:

I volunteer at a non profit agency. They have a couple doors which do not
have windows, but they would like them to have windows. Metal doors, *36
inch wide, heavy. Fitted for full mortise lock.


Christopher A. Young
Learn more about Jesus
*www.lds.org
.

I would try asking on Craigslist for exterior doors with windows.
They are most likely standard 3 foot wide doors, but measure them and
say what size you are looking.

I love the listings on Craigslist for tires. They usually have no
information on the size.


Dan

On Thu, 26 Jan 2012 17:45:41 -0600, Jon Elson wrote:

Stormin Mormon wrote:

As I make this "new post", I realize I'm way short of details. I'll rely
on you all to ask a lot of questions, and I'll get the details as we go.

I volunteer at a non profit agency. They have a couple doors which do not
have windows, but they would like them to have windows. Metal doors, 36
inch wide, heavy. Fitted for full mortise lock.

If the window is available separately, looks like a case of drill the
corners of the hole I need. use my electric nibbler to remove the
rectangle shaped piece of heavy sheet metal. Put the two halves of the
window up, and tighten some screws.

Anyone done this? Tips, cautions, etc?
My experience with a couple metal doors is that they use the hardest
stuff imagineable. Something like a cross between safe metal and the
stuff bedframe rails are made of. REALLY hard on cutting tools. You
can drill it with Cobalt drills, but typical sawzall blades will go dull
in about an inch of cutting, I think.

Jon

When I was running the alarm company..I did a number of them. The doors
are soft as butter or armor plate. Best thing Ive found is a die grinder
and the 3" cut off wheels held really really firmly. Cuts pretty quickly
though. Do a shallow pass all the way around, which helps the next deep
pass stay lined up.

Hint..measure from one edge of the door..the same edge on both sides
when laying out the window. Nothing worse than having one side 3/16"
offset from the other.

I typically would cut out one side, use a corner square to mark the
inside of the other side..G..and then center punch the proper places,
then go to the other side of the door, and make the window markings on
that side, using the center punchmarks which are now little pimples on
your side. Seems to help keep everything squared up quickly.

You really cant use a sawzall..because the blades are too long, so you
have to cut them off and then cut. And do NOT try to cut both sides at
the same time with a sawzall. Aint happening. That blade will slant out
one way or another inside the door and screw you up big time.

Measure, marke well and then cut.

Now..if you have a plasma cutter..shrug..might work..but some of those
doors have cardboard or even asbestos inside for sound deadening. If it
was asbestos..your golden. Cardboard..with a plasma cutter..and you have
a door on fire inside. Screws up the paint and makes a nasty stink

Gunner


Gunner

One could not be a successful Leftwinger without realizing that,
in contrast to the popular conception supported by newspapers
and mothers of Leftwingers, a goodly number of Leftwingers are
not only narrow-minded and dull, but also just stupid.
Gunner Asch

On 1/26/2012 4:57 PM, Stormin Mormon wrote:
As I make this "new post", I realize I'm way short of details. I'll rely on
you all to ask a lot of questions, and I'll get the details as we go.

I volunteer at a non profit agency. They have a couple doors which do not
have windows, but they would like them to have windows. Metal doors, 36
inch wide, heavy. Fitted for full mortise lock.

If the window is available separately, looks like a case of drill the
corners of the hole I need. use my electric nibbler to remove the rectangle
shaped piece of heavy sheet metal. Put the two halves of the window up, and
tighten some screws.

Anyone done this? Tips, cautions, etc?

Christopher A. Young
Learn more about Jesus
www.lds.org
.




The bigger deal is finding the metal frame. The terms in the industry
are "vision panel" and "half light". Anyone who deals in hollow metal
should have the kits or be able to get them. They do NOT normally
supply the glass so you are looking for 2 suppliers. I prefer the 2
piece metal kits, put the screws on the not locked side.

It makes a bit of difference what grade of door and more so what filler
is in the door. As others have said, many weapons will work.
--


___________________________________

Keep the whole world singing . . .
Dan G
remove the seven

Would you work with the door flat, on a bench, or sawhorses? I guess you'd
have to, using a circle saw. I hadn't thought of that, I was mostly thinking
of cutting the door while it's still on the hinge.

Thank you for sharing your metal working experience.

Christopher A. Young
Learn more about Jesus
www.lds.org
..

"Lloyd E. Sponenburgh" lloydspinsidemindspring.com wrote in message
. 3.70...

naaahhh... I've cut custom openings in steel doors many times!

I've used a fine-toothed carbide blade in a circular saw, cutting VERY
slowly to prevent the saw from yanking up a rough edge. "Ferrous metal"
cutting blades work, too, but tend to burn the foam in the door. Grit
blades work great!

I've also used a 24T metal cutting sabre saw blade (in a sabre saw, yes).
Works fine. Again, high saw speed, SLOW cutting.

It's very easy to do a good job, if you keep the rate of feed low and
very controlled -- don't let the saw pull itself into the work.

LLoyd

It's worth asking, I guess. I think these are 36 inches wide, not sure the
height.

Listing tires without listing the size, sounds like a waste of a perfectly
good ad.

Christopher A. Young
Learn more about Jesus
www.lds.org
..

wrote in message
...

I would try asking on Craigslist for exterior doors with windows.
They are most likely standard 3 foot wide doors, but measure them and
say what size you are looking.

I love the listings on Craigslist for tires. They usually have no
information on the size.


Dan

We might know who is the supplier who provided the doors in the first place,
so might be possible to get the same kind of window.

At this point, looks like we'll exchange two doors, one for the other.
Another door was found in the barn, which has a window, and the same handing
as the door coming out.

I'm still curious to learn. Even if I might not actually do the window
install.

Christopher A. Young
Learn more about Jesus
www.lds.org
..

"DanG" wrote in message
...


The bigger deal is finding the metal frame. The terms in the industry
are "vision panel" and "half light". Anyone who deals in hollow metal
should have the kits or be able to get them. They do NOT normally
supply the glass so you are looking for 2 suppliers. I prefer the 2
piece metal kits, put the screws on the not locked side.

It makes a bit of difference what grade of door and more so what filler
is in the door. As others have said, many weapons will work.
--


___________________________________

Keep the whole world singing . . .
Dan G
remove the seven

"Stormin Mormon" fired this volley
in news
Would you work with the door flat, on a bench, or sawhorses? I guess
you'd have to, using a circle saw. I hadn't thought of that, I was
mostly thinking of cutting the door while it's still on the hinge.


I've done it both ways, but it's easier to work on the flat.

Also, cover all exposed surfaces around the cut with masking tape or safety
tape, to prevent marring the remaining surfaces.

LLoyd

Oy, protect other surfaces. You're so right. My experiences with modifying
wood doors, requires very careful technique, and were a bit of a learning
experience. I learned that a 1 x 4 can be clamped to the door, to guide the
back edge of the saw. A 2 / 4 is too high, the motor won't clear.

Christopher A. Young
Learn more about Jesus
www.lds.org
..

"Lloyd E. Sponenburgh" lloydspinsidemindspring.com wrote in message
. 3.70...

I've done it both ways, but it's easier to work on the flat.

Also, cover all exposed surfaces around the cut with masking tape or safety
tape, to prevent marring the remaining surfaces.

LLoyd

On Fri, 27 Jan 2012 07:51:05 -0600, "Lloyd E. Sponenburgh"
lloydspinsidemindspring.com wrote:

"Stormin Mormon" fired this volley
in news
Would you work with the door flat, on a bench, or sawhorses? I guess
you'd have to, using a circle saw. I hadn't thought of that, I was
mostly thinking of cutting the door while it's still on the hinge.


I've done it both ways, but it's easier to work on the flat.

Also, cover all exposed surfaces around the cut with masking tape or safety
tape, to prevent marring the remaining surfaces.

Ditto. A circ saw with a fresh throwaway blade is great for that,
too. Just wear eye and ear protection.

--
Creativity can solve almost any problem. The creative act,
the defeat of habit by originality, overcomes everything.
-- George Lois

WHAT!!! CAN'T HEAR YOU!!!! AND WNOE, AND HAERELDY SEE THE SDRESEN TO TYPE,
THES;ER SEFRAY GLASESE SARE SO SCRATCERHEHED UP!!!!!

Christopher A. Young
Learn more about Jesus
www.lds.org
..

"Larry Jaques" wrote in message
news
Ditto. A circ saw with a fresh throwaway blade is great for that,
too. Just wear eye and ear protection.

--
Creativity can solve almost any problem. The creative act,
the defeat of habit by originality, overcomes everything.
-- George Lois

"Stormin Mormon" fired this volley in
:

Just wear eye and ear protection

Stormy, you laugh, but the rule of cutting sheet metal with a toothed
circular saw is, "it hurts" (pretty much everything on your body).

Wear long sleeves, and button up your top collar button, too!

DAMHIKT!

Lloyd

You know, that does sound like the voice of experience. Thanks for trying to
help me avoid similar pains. I've found that cutting metal usually involves
sparks, and all kinds of bad things.

Christopher A. Young
Learn more about Jesus
www.lds.org
..

"Lloyd E. Sponenburgh" lloydspinsidemindspring.com wrote in message
. 3.70...

Stormy, you laugh, but the rule of cutting sheet metal with a toothed
circular saw is, "it hurts" (pretty much everything on your body).

Wear long sleeves, and button up your top collar button, too!

DAMHIKT!

Lloyd

On 1/27/2012 7:27 AM, Stormin Mormon wrote:
We might know who is the supplier who provided the doors in the first place,
so might be possible to get the same kind of window.

At this point, looks like we'll exchange two doors, one for the other.
Another door was found in the barn, which has a window, and the same handing
as the door coming out.

I'm still curious to learn. Even if I might not actually do the window
install.

Christopher A. Young
Learn more about Jesus
www.lds.org
.

wrote in message
...


The bigger deal is finding the metal frame. The terms in the industry
are "vision panel" and "half light". Anyone who deals in hollow metal
should have the kits or be able to get them. They do NOT normally
supply the glass so you are looking for 2 suppliers. I prefer the 2
piece metal kits, put the screws on the not locked side.

It makes a bit of difference what grade of door and more so what filler
is in the door. As others have said, many weapons will work.


Before you drag that heavy beast from the barn, check the hinge layout
and the strike height. There are no two door manufacturers that use the
same layout. If all the doors were bought at one time and are all
original you are probably good to go, but certainly check. If the
hinges won't make, you can go to 1/2 mortise or 1/2 surface hinges or
one of the newer continuous hinges. Continuous hinges are over $100.

Best of luck.

--


___________________________________

Keep the whole world singing . . .
Dan G
remove the seven

"Stormin Mormon" wrote:

As I make this "new post", I realize I'm way short of details. I'll rely on
you all to ask a lot of questions, and I'll get the details as we go.

I volunteer at a non profit agency. They have a couple doors which do not
have windows, but they would like them to have windows. Metal doors, 36
inch wide, heavy. Fitted for full mortise lock.

If the window is available separately, looks like a case of drill the
corners of the hole I need. use my electric nibbler to remove the rectangle
shaped piece of heavy sheet metal. Put the two halves of the window up, and
tighten some screws.

Anyone done this? Tips, cautions, etc?

You might ask yourself WHY were they metal doors in the first place,
and WHY do they want windows.

There might be better solutions
jk

On Sat, 28 Jan 2012 11:53:13 -0800, jk wrote:

"Stormin Mormon" wrote:

As I make this "new post", I realize I'm way short of details. I'll rely on
you all to ask a lot of questions, and I'll get the details as we go.

I volunteer at a non profit agency. They have a couple doors which do not
have windows, but they would like them to have windows. Metal doors, 36
inch wide, heavy. Fitted for full mortise lock.

If the window is available separately, looks like a case of drill the
corners of the hole I need. use my electric nibbler to remove the rectangle
shaped piece of heavy sheet metal. Put the two halves of the window up, and
tighten some screws.

Anyone done this? Tips, cautions, etc?

You might ask yourself WHY were they metal doors in the first place,
and WHY do they want windows.

There might be better solutions

I'm wondering why he didn't simply ask Jesus. shrug


--
The most decisive actions of our life - I mean those that are most
likely to decide the whole course of our future - are, more often
than not, unconsidered.
-- Andre Gide

Larry Jaques wrote:


There might be better solutions

I'm wondering why he didn't simply ask Jesus. shrug

Because Jesus would say "build a wooden door"???
jk

On Sat, 28 Jan 2012 13:16:29 -0800, Larry Jaques
wrote:

On Sat, 28 Jan 2012 11:53:13 -0800, jk wrote:

"Stormin Mormon" wrote:

As I make this "new post", I realize I'm way short of details. I'll rely on
you all to ask a lot of questions, and I'll get the details as we go.

I volunteer at a non profit agency. They have a couple doors which do not
have windows, but they would like them to have windows. Metal doors, 36
inch wide, heavy. Fitted for full mortise lock.

If the window is available separately, looks like a case of drill the
corners of the hole I need. use my electric nibbler to remove the rectangle
shaped piece of heavy sheet metal. Put the two halves of the window up, and
tighten some screws.

Anyone done this? Tips, cautions, etc?

You might ask yourself WHY were they metal doors in the first place,
and WHY do they want windows.

There might be better solutions

I'm wondering why he didn't simply ask Jesus. shrug
He did ask Jesus. He said "Why do you think I told William Shockley
about transistors? It was so you could use you computer and ask rcm!"

On Sat, 28 Jan 2012 13:55:09 -0800, jk wrote:

Larry Jaques wrote:


There might be better solutions

I'm wondering why he didn't simply ask Jesus. shrug

Because Jesus would say "build a wooden door"???
jk

Someone might want to point out the link that shows how big a cubit is
though.....


One could not be a successful Leftwinger without realizing that,
in contrast to the popular conception supported by newspapers
and mothers of Leftwingers, a goodly number of Leftwingers are
not only narrow-minded and dull, but also just stupid.
Gunner Asch

Gunner Asch on Sat, 28 Jan 2012 19:58:05 -0800
typed in rec.crafts.metalworking the following:
On Sat, 28 Jan 2012 13:55:09 -0800, jk wrote:

Larry Jaques wrote:


There might be better solutions

I'm wondering why he didn't simply ask Jesus. shrug

Because Jesus would say "build a wooden door"???
jk

Someone might want to point out the link that shows how big a cubit is
though.....

"Whats a cubit?"
Lets see a cubit...I used to know what a cubit was
Well don't worry about that Noah.

It's about three palms in length. Or 48 cm +/- 2 inches
--
pyotr
Go not to the Net for answers, for it will tell you Yes and no. And
you are a bloody fool, only an ignorant cretin would even ask the
question, forty two, 47, the second door, and how many blonde lawyers
does it take to change a lightbulb.

The paid guy painted the door they found in the barn. Put that into the one
door jamb. The other two doors got swapped. Now, one needs some mystery glue
taken off the window, it's hard to see through. He figures to do that with a
razor scraper. I got to help put the one door in, helped steady the door,
and get the screws started. Project is essentially complete.

The whole building is metal doors. Not sure why they wanted windows.

Christopher A. Young
Learn more about Jesus
www.lds.org
..

"Larry Jaques" wrote in message
...


You might ask yourself WHY were they metal doors in the first place,
and WHY do they want windows.

There might be better solutions

I'm wondering why he didn't simply ask Jesus. shrug


--
The most decisive actions of our life - I mean those that are most
likely to decide the whole course of our future - are, more often
than not, unconsidered.
-- Andre Gide

On Sun, 29 Jan 2012 08:15:28 -0500, "Stormin Mormon"
wrote:

The paid guy painted the door they found in the barn. Put that into the one
door jamb. The other two doors got swapped. Now, one needs some mystery glue
taken off the window, it's hard to see through. He figures to do that with a
razor scraper. I got to help put the one door in, helped steady the door,
and get the screws started. Project is essentially complete.

The whole building is metal doors. Not sure why they wanted windows.

Christopher A. Young
Learn more about Jesus
www.lds.org

Perhaps to see through? Just in case the Rapture occurs and nobody
notices it.


One could not be a successful Leftwinger without realizing that,
in contrast to the popular conception supported by newspapers
and mothers of Leftwingers, a goodly number of Leftwingers are
not only narrow-minded and dull, but also just stupid.
Gunner Asch

In article , "Lloyd
E. Sponenburgh" says...

"Stormin Mormon" fired this volley in
:

Just wear eye and ear protection

Stormy, you laugh, but the rule of cutting sheet metal with a toothed
circular saw is, "it hurts" (pretty much everything on your body).

Wear long sleeves, and button up your top collar button, too!

DAMHIKT!

And wear something that you can either throw away or reserve for that
kind of job. The little metal bits don't all come out in the wash and
when they do they'll get in anything else that's in the wash, like your
socks and underwear.

DAMHIKT!