Tell me if this is possible

[Salty]

Hello all, and thanks in advance.
I need to cut a saw kerf in the jamb of an existing entrance door. The old weatherstriping is set into a saw kerf that is in a direction that is parallel to the frame, shown in black below. The new weatherstrip needs a kerf at 90 degrees to the frame, shown in green below. I have not been able to find a replacement weatherstrip since the door is no longer made. The old one is magnetic and over the years the previous owner painted the door and the weatherstrip while the door was closed. Thus it is no longer flexable and will not correctly conform to the door. It is also torn in several places.
I have some of the newer vinly foam type weatherstrip that is used on new doors but I need to cut this kerf. It has to be directly in line with the inside edge of the jamb, where the door meets the offset. I have tried a thin handsaw but it proves too much for my arms to endure. The only tool I can think of that would do it is a saw blade in a Fein saw as I think those can cut flush to the surface. But I really didn't want to spend a lot of money on a tool for one small job.
Any ideas of how I can get that kerf sawn into this jamb?

[bigfoot]

dremel, angle grinder with a blade in place of wheel, hammer + chisel + time, Otherwise keep looking for the right weatherstripping, That is not ussually proprietary, the weatherstrip is usually bought by the door mfg. and just installed on the casing. I think you need to look for weatherstrip manufacturers, and forget the door company.

[JimD]

I would use a full sized hand saw. If sharp, it should not take more than 10 minutes.

Jim

[Salty]

Good suggestions, but I'm afraid they won't work. All of the Dremel and other rotary tools have a bolt or scrw head that would prevent the slot from being flush with the wood. Also. I don't like the idea of a spinning blade large enough to bridge the distance needed to clear the retaining fastener. That would be about 4" diameter.
A full size hand saw would make a kerf too wide for the insert. It needs to be about 1/16" for the tang to seat properly.
And I have looked far and wide for weatherstrip like this but have not found one with the profile in the needed orientation. All of them go the other way.
Thanks though.

[bigfoot]

A better picture or diagram would help. I looked at this one again, and I have no idea what perspective I am seeing.

http://www.technologylk.com/products...tegory_ID=1209

Try that link, I think I saw three different items that would work right there.

Or this one-
http://www.buypemkoonline.com/orderi...OVMTC=standard

They claim 5000+ items.

That was after a 20 second search, it took me longer to type this.
I have no doubt the local HD doesn't have the right stuff, they never do. But I also have no doubt that someone does.

If all else fails, here are the search results
http://us.search.yahoo.com/search?ei...atherstripping

If THAT doesn't work, then find something in a screw on flanged type, I mean, it's a door, not brain surgery.

[cgallery]

Flush-cut saw.

http://www.rockler.com/product.cfm?page=5322

[Tom Slick]

I just installed a pre-hung door with that type of seal so I know what you are talking about but my door already had the groove. You need a slot cutter with a flush bottom and a bearing above the cutter. I don't know where to find one with a 1/16" kerf though.

This pic is from MLCS, their smallest model listed is 1/8" kerf.