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Running a CrossFit Facility Tips and guidance on how to open and operate a CrossFit gym.

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Old 04-12-2013, 06:34 AM   #1
Drew Kite
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Cutting Stall Mats

Does anyone know of a good way to cut stall mats? I can't think of any way to cut them that wouldn't be a total pain in the *** but I'm sure someone out there knows of a way.
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Old 04-12-2013, 06:52 AM   #2
Bryan Kemper
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Re: Cutting Stall Mats

Very sharp knife, good straight edge (L-square is best) and patience...
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Old 04-12-2013, 07:49 AM   #3
Mike M. Jones
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Re: Cutting Stall Mats

How clean of an edge do you need, I don't have the patience of so for edge pieces I used a sawzall... Interior square cuts around a post I drilled pilot hole and my jigsaw cut through it like butter. Tip though is to use a blade with big teeth so the rubber doesn't gunk up the blade too much, also I would take it outside and have someone run a cold hose of the cutting area while you are cutting as a coolent or the rubber will melt with the friction (think homemade wet saw) Take a file and clean off the edges . I did about 6 mats in 10mins, barring that the old utility knife straight edge and lots of patience like the other poster said.

also old post with plenty of good ideas:

http://board.crossfit.com/showthread.php?t=66395

Last edited by Mike M. Jones; 04-12-2013 at 07:53 AM..
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Old 04-12-2013, 11:37 AM   #4
Lincoln Brigham
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Re: Cutting Stall Mats

Putting a slight bend in the stall mats makes them easier to cut by orders of magnitude.
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Old 04-12-2013, 02:05 PM   #5
Tommy Alfinito
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Re: Cutting Stall Mats

A long metal measuring stick, utility knife, a few packs of blades, and wd-40. I did 5000 square feet of edges this way. Once the blade dulls, change it. The wd-40 seemed to help on some mats that were giving me trouble. You need a measuring stick so you can just run the blade right along it.
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Old 04-12-2013, 06:35 PM   #6
Jonathan Kinnick
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Re: Cutting Stall Mats

We put a 2x4 under the mat, in line with the metal straight edge on top. This is an easy way to get the bend in the mat that Lincoln was referring to above. Don't be stingy trading out new blades. I like to do a bunch of quick strokes, maybe a foot or two each, and then work my way across the mat. Works pretty well.
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Old 04-13-2013, 01:30 PM   #7
Silviu Bona
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Re: Cutting Stall Mats

My fave is a cheap fillet knife from bass pro. 15$ and a straight pie e of metal like an angle or something.
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Old 04-13-2013, 07:49 PM   #8
Mauricio Leal
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Re: Cutting Stall Mats

Very sharp utility knife with a straight edge as others have said. But I'd add that having a spray bottle of water to lubricate the seam that forms after a few initial passes makes it way easier to finish the cut.
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Old 04-14-2013, 06:13 AM   #9
Jackson Harmer
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Re: Cutting Stall Mats

I recently used a small hand hacksaw with great results. Having a second person to hold up one end and peel it back as you cut made it very fast and easy.
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Old 04-15-2013, 08:04 AM   #10
Christopher Morris
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Re: Cutting Stall Mats

Quote:
Originally Posted by Jonathan Kinnick View Post
We put a 2x4 under the mat, in line with the metal straight edge on top. This is an easy way to get the bend in the mat that Lincoln was referring to above. Don't be stingy trading out new blades. I like to do a bunch of quick strokes, maybe a foot or two each, and then work my way across the mat. Works pretty well.
I second the use of a 2x4. Stand it up long ways under the mat to maximize the bend. Work with someone else. One of you bend the mat over the 2x4, the other cut with short strokes.

I haven't used a metal L-straightedge like others, but that's a great idea. Instead, I snap a chalk line on the mat (because I already had one on hand), and then cut along the chalk.
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