Hi Forum I need to create a custom sized L shaped corner post to finish off my kitchen. I've got a spare door that's not needed so though I could cut a length of each end of that. It a white high gloss vinyl finished door. I've read this very useful post but got sort of lost towards the end. I've got access to a circular saw and a friend with some experience using it and picked the following suggestions out. Don't think I have access to a router. 1/ Nick the exit edge to avoid breakout 2/ Put the door upside down - clamp it between two pieces of mdf and cut through all three 3/ Cut it close with a fine toothed circular saw with a nice sharp blade 4/ Set the blade depth so it's just about 5mm or so through the door 5/ Don't try to zip through it as quick as you can 6/ Finish the last few mm with a sanding block Does that sound like it might work? Thanks
Whatever you use, you can do a test cut down the centre of the door first. You only need one decent edge due to the overlap, but if you do get a bit of chip out, then a bit of silicone or caulk run up the corner will disguise it
Where abouts are you? Happy to cut it for you if you are nearby. I do this often to make custom sized posts. Track saw makes it easy with a fine finish.