Cutting rubber horse stall mats

TheMan419 · Apr 9, 2017

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?

farmeratheart · Apr 9, 2017

When I cut that thick stall mat to use for my snowplow edge, I used a saber saw with the coarsest blade I had on hand. I used the slower blade speed setting and cut along the edge of a 2x6 underneath to get a straight finish. A saber saw would be good for making your stall post notches too!

Good Luck,

Frank

RNeumann · Apr 9, 2017

The low speed, course blade is needed to prevent melting. My impatience would have me mask up and "make" a bunch with my skil saw and then go directly to the shower.

Redlands Okie · Apr 9, 2017

Yep. Same as the others. Jig saw, saws all, hole saw. Wood blade moderate speed. Circular saw works also but use a old blade so u not mess up a new one. Back side up of the mat not a bad idea while cutting.

boggen · Apr 9, 2017

table saw would be my first thought. second thought a circular saw might work.

jig saw, skillsaw, or reciprocating saw, would go with a jig saw. for a more accurate cut. trying to get a reciprocating saw down a long line has always been a challenge for myself mainly due to the size/shape of the reciprocating saw itself does not lead for long straight lines.

General Lee · Apr 9, 2017

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.

PILOON · Apr 9, 2017

I once lined some 30 box stalls and tried just about everything.
What ended up the most productive for long cuts was to lay the rubber mat over a 2 x 4 and use an OLFA knife to cut from top side.
The 2 x 4 sort of let the cut open up making slitting rather easy.
When ever I tried power tools heat became the enemy causing binding. Soap did help as a lubricant somewhat.
All in all I decided that there was no power tool for doing that chore.

Spindifferent · Apr 9, 2017

Box cutter and lots of blades.

Soggy Bottom Outdoors · Apr 9, 2017

If you use a knife, pocket, butcher, skinning, hunting. Make sure the blade is very sharp and keep it wet by lots of dripping in a cup/bucket of water. If you have the help and the situation allows someone can dribble a little water over the blade as you cut. Be safe. My FIL retired from Gates Rubber Company after 32 years and he said that's how they cut hoses, belts, mats, etc.

oosik · Apr 9, 2017

There have been threads on this previously. My memory can't dredge up exactly what was used to cut. Perhaps a thread search........

Rustyiron · Apr 9, 2017

It may have been a different rubber compound but I had no trouble with a skill saw set only an 1/8 deeper cutting into a 2x directly under the cut. It was my regular carbide 18 tooth framing blade. (red freud Diablo)

s219 · Apr 9, 2017

I have cut it a few different ways. Darn near ruined a table saw blade, although it did cut fine. But the blade was gummed up with black rubber that later would get on wood when cutting. Took years for all that rubber to wear off the blade.

The easiest way I found was with a utility knife with a new sharp blade. Took 2-3 cuts to get all the way through, but worked fairly well and was quick.

Zerk · Apr 9, 2017

I cut some 3/4, to make strips on sides of my bike. 2x4 underneath, each side of cut, few inchew away or more. Just want it off ground. Then I clamped 2x4 on top for straigh edge. Ran down it with sawzall. Went really quick. Smelled like burnt rubber for a bit.

I tried old circ saw, first few inches, were ok, then collapsed. Maybe different blade. But sawzall was exteremly fast, would not hesitate to do it this was. Wouldn't bother with another, for myself.

You got to be bug crazy to even think about a knife. Why???

s219 · Apr 9, 2017

Zerk said:
You bug crazy to even think about a knife. Why???

Honestly, it was a piece of cake with a knife. I'd do it that way again for sure. This isn't a tire or molded rubber -- it's pressed rubber.

RobertBrown · Apr 9, 2017

Try an electric carving knife with WD 40

Creamer · Apr 9, 2017

s219 said:
Honestly, it was a piece of cake with a knife. I'd do it that way again for sure. This isn't a tire or molded rubber -- it's pressed rubber.

Having worked in the rubber industry I totally agree. A good sharp smooth edged knife. A rolling knife like the OLFA works as well. Makes a slick clean cut and as S219 said 3 strokes with a very sharp utility knife and you are through. very quick. But change your blades often they dull very quickly.

Water, light oil, butter etc help some but if you have it so the cut opens slightly and the knife does not drag it is very easy. The work is getting the rubber the slip along on the sides of the knife - not the actual cutting.

QRTRHRS · Apr 9, 2017

One thing no one has mentioned about cutting stall mats is to cut them about a quarter of an inch undersized. They can buckle with warm weather but worse, if you are putting them in for horses is if a horse somehow dislodges one. Even tight, dirt can get into the seams and make it hard to get that displaced one back down flat. With a little gap, you can remove the whole mat, scrape and sweep around the parimeter and drop the mat right back into place.

Also, a couple of channel locks or visegrips make dragging those 100lb mats a bit easier.

two_bit_score · Apr 9, 2017

If you have a Fein multi master or similar tool they make a blade for that.

639�32�5�15, Fein Multimaster Convex Segment Blade

63903205015, Fein Multimaster Convex Segment Blade For cutting rigid material, e.g. plastic, linoleum, rubber, cardboard, leather, wire mesh, wall-to-wall carpet, and much more.

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comancheflight · Apr 9, 2017

I used the horse stall mats for an exercise room and also cut them for my 8' blade...used a razor blade knife. Was a piece of cake and made beautiful cuts. One blade pretty much did it all..
Like one poster said, I used a 2 X 4 to help open the cut wich make the razor slide easily. It takes a few stokes with a straightedge but is a quick process.