Shorten a Hollow Core Door
This takes just some simple woodworking. I purchased a hollow core door that I wanted to cut down to a more reasonable size. I have done this operation before so I knew what I had to do to make it a finished project.
The store clerk cut the door off 20 inches for me but it was my job to fix the now gaping wide open ends. It was a Hollow Core door after all.
I used my Powermatic table saw to cut down and square up some saved scrap wood I had in the shop. It was a good reason to put the blade guard back on the saw as the fence would be close to the blade. I didn't want this little project to end with a tragic event. I actually like my fingers. A previous project required I remove the guard.
A press tight end to end fit of the new insert is not required as the skin provides the rigidity not the corner butt splice. The skin functions the same as a gusset in the corner. The corner isn't going anywhere once the glue sets.
It's not too difficult to adjust the height of a hollow core door. I just don't let the gaping hole worry me too much after the end is cut off. The wood pieces are rather thin so there is not much wood to work with when cut down. I am aware that there is extra solid material in most hollow core doors where the door knob hardware is installed. I must be sure to cut off the proper end of the door to maintain the proper doorknob height if this was going to be used as an actual door.