Cut Out the Seating Area
Once you get your new tub home it’s time to cut out the front for the seating area. The insides of cast iron tubs are lined in brittle porcelain, which can be hazardous as it flakes off during the cutting process. To help thwart this, I applied masking tape to the entirety of the cut area.
To make the cut you’ll need a 4-1/2” angle grinder and metal cutoff wheels. Also imperative here is adequate eye protection (a face shield is best), hearing protection, and gloves. This is serious business here; a piece of hot metal flying off the cutoff wheel at tremendous speed can rob you of your eyesight. Always wear your personal protective equipment.
After laying out the cut area on the tub and gathering your tools, you can begin cutting. Plan your cuts so that you don’t bind the cutoff wheel toward the end of the cut or run the risk that the heavy section that is being removed fall, which could injure you or crack your tub. A helper to support the section being removed is helpful.
After removing the tub side at the seating area with the cutoff wheel, you’ll need to switch to a regular grinding disk on the grinder and dress the cut edges to remove any burrs or ragged edges.
Paint the Tub
The hard work is now complete. Now you can paint the tub in your choice of colors. We primed the cut areas first and then chose a heavy duty oil-based enamel for durability’s sake.