Cutting rubber horse stall mats

[TheMan419]

Thanks all. Carpet knife was $4 at big box store. Comes w 5 blades each blade being able to be rotated to have 2 of not 4 cutting edges. So will try that and the reciprocating saw.

The 2x4 underneath and on top for sure. Got to have a straight(ish) cutting edge.

 

[Argonne]

If I was doing it again, I would seriously consider making the stalls of a dimension that whole mats would drop in without cutting. Not that "dropping them in" is particularly easy either. Everything associated with installing those things I consider a PITA, but I also consider them worth the expense and trouble.

 

[TheMan419]

If I was doing it again, I would seriously consider making the stalls of a dimension that whole mats would drop in without cutting. Not that "dropping them in" is particularly easy either. Everything associated with installing those things I consider a PITA, but I also consider them worth the expense and trouble.

Yeah the problem is that a 12x12 stall is never exactly 12x12 and the 4x6 mat is never exactly 4x6. Plus no matter you are going to have posts to account for.

Just moving them is a pain. However, having been in barns both with and without mats the mat is the way to go. Cleaning a stall with a mat is just a breeze compared to cleaning one without. Not that it is too expensive, but you use less shavings as well.

 

[Gem99ultra]

My experience with 3/4" horse mat cutting has been pretty much all bad. Cutting with a circular saw and/or a table saw at first glance seems to be the ideal way to hack through those mats. And, with the addition of a little WD40 sprayed on during the process, I did get them cut. BUT - cleaning up the now dull blades was not a minor task.

Using a box blade worked pretty good on notches, but does require several cuts to get all the way through the mat. My jig saw with a course blade running a bit slow seemed to work probably the best. You can figure on throwing away any saw blade that you use though.

Horse mats are really great, but all-in-all, they're a pain to cut to fit. Hopefully you'll give us your final judgement on just which method of cutting worked best for youj.

 

[TheMan419]

My experience with 3/4" horse mat cutting has been pretty much all bad. Cutting with a circular saw and/or a table saw at first glance seems to be the ideal way to hack through those mats. And, with the addition of a little WD40 sprayed on during the process, I did get them cut. BUT - cleaning up the now dull blades was not a minor task.

Using a box blade worked pretty good on notches, but does require several cuts to get all the way through the mat. My jig saw with a course blade running a bit slow seemed to work probably the best. You can figure on throwing away any saw blade that you use though.

Horse mats are really great, but all-in-all, they're a pain to cut to fit. Hopefully you'll give us your final judgement on just which method of cutting worked best for youj.

I will report back. Project likely to happen this weekend. Currently I am leaning toward reciprocating saw and just tossing the blade when done.

 

[tallyho8]

I've cut many stall mats and tough grain elevator mats and tried everything but the best way I found is with a utility knife, keeping the blade wet with diesel for a lubricant. As long as the blade is wet it cuts easy and the blades don't dull too quick.
Having a helper with a squirt bottle of diesel as you go along makes it much easier.

 

[Ed L]

Use a Jigsaw and these.......

T113A3 | 3 pc. 4 In. Knife Edge Special for Soft Materials T-Shank Jig Saw Blades | Bosch Power Tools

Ed

 

[Soundguy]

Rubber mat is 3/4 inch thick. Each piece is 4'x6'. Some will have to be trimmed shorter. Others will have to be notched to go around the stall posts.

One thought is to use a carpet knife.

What about a reciprocating saw? If so what blade? I am thinking for the cuts that have to go the entire length of the mat to chalk a line. Then put a 2x4 under the mat and one over the mat to sandwich it. Use that as a cutting guide and hit it with the saw?

For the cuts around the posts the carpet knife might be needed?

Anyone have any advice?

i've use a fine cut circular, a sawsall with wood teeth, and a jig saw with wood teeth. all worked. circular saw makes a little smoke.. etc.

 

[JRobyn]

Use a Jigsaw and these.......

T113A3 | 3 pc. 4 In. Knife Edge Special for Soft Materials T-Shank Jig Saw Blades | Bosch Power Tools

Ed

Those should work dandy. I once had to cut a bunch of foam rubber sheet about 1"-2" thick. Needed those blades but could not find any so ground the teeth off a regular blade and sharpened.

 

[Garandman]

I've used a razor knife with a straight edge. But only had to work a few pieces. Did the the job but takes several strokes to get through and changing the blade frequently helps.

And water.