How To Cut A Bath Panel

Cutting a bath panel can be a straight-forward task providing you have the right tools and patience to do the job. Below is a clear step-by-step guide that outlines what you need to do.

It’s important to note that you need to have the appropriate PPE (like safety glasses, dust mask/respirator and ear protection) before following the steps below.

Step 1. Measure for size

You will need to measure the height, length and depth of your bath panel to ensure it fits correctly.

Height - measure from the finished floor surface to the underside of the bath using your tape measure. Don’t include the bath frame or the underside of the base. Make sure you write the measurements down as you go so you don’t forget. 

Top tip: do this a few times in different places (left/centre and right) to ensure measurements are exact. Floors may slope and tiles may not be level, so it’s important that you are precise when measuring.

Length - measure from the wall/tile face to the bath edge. Don’t include the skirting or behind the tiles. 

Top tip: you could use a spirit level to ensure the bath is level/if the floor slopes - this can confirm if your measurements are correct or need to be adjusted.

When you have the exact measurements, you can subtract 2-3mm to ensure you don’t have to force it into place. Allowing a tiny gap means you can effortlessly slide it into place, and caters for wiggle room without struggle.

Step 2. Mark the cut line

Once you have the correct measurements, you will need to mark where you need to cut. Firstly, you will need to lay the panel flat on a stable, level surface, and measure from the bottom edge up. It’s a good idea to mark several points (ideally 5), across its width to ensure your line will be level. Connect these points using a straight edge/ruler or spirit level to create your straight line.

Top tip: it can be helpful to apply masking tape, by redrawing over the line to prevent chipping when you cut.

Step 3. Cutting the panel

Before cutting the panel, you need to double check you’re happy with your measurements and marking before proceeding. Once you’re ready, you’ll need to place the bath panel on a flat workbench or stable surface and clamp to secure. The tool you will use depends on the material of the bath panel.

Jigsaw - this is the best and easiest way of cutting your bath panel accurately. Firstly, ensure you are using a fine-tooth blade (suitable for the material) and position the jigsaw so that the blade sits on the edge of your marked line. Steadily guide the jigsaw along the edge of the line keeping the base plate flat against the panel. Don’t push too hard as the blade should do most of the work. When approaching the end of the cut, support the offcut with your hand to avoid damaging the edge.

Top tip: Never cut directly on the line as you may cut too short - it’s always better to air on the side of caution and trim later if needed.

Once you’re happy with your cut, lightly sand to remove any roughness, taking care not to round it over. Make sure you wipe down and clean off any dust and test-fit the panel to ensure you can gently slide into place without force. If the panel is MDF you’ll need to seal the cut edge with PVA, primer or varnish to protect it before fitting.

Cutting a bath panel for pipes takes a bit more care than adjusting the height/or length. Although it’s a manageable DIY task, it will take an element of skill and precision to ensure it fits perfectly. 

Preparation before cutting your bath panel

Firstly, it’s important to decipher if you need to cut the bath panel for a visible pipe (like a waste pipe), or do you need consistent access to valves and traps - in which case, it may be beneficial to create a removable access panel (instead of a cut-out).

Once you’ve decided how you want your panel, you’ll need to take measurements.

1. Measure from the floor to the centre of pipe

2. Measure from the nearest wall to centre of pipe

Double check that you’re happy with the measurements and then mark it out on your bath panel in preparation for cutting. You might want to trial it out first with a cardboard template or something similar - just to ensure it fits correctly before cutting your bath panel

Cutting methods

You now need to decide which tool is best to cut your bath panel. For small, round pipes it’s best to use a hole saw, and for larger shapes (or access to traps/valves) it’s best to use a jigsaw. See below for further guidance on each method.

Round pipes:

This method is best to use on waste pipe sized holes (32mm or 40mm), or a straight pipe passing through the panel. 

1. Once you have your accurate measurements, you will need to mark the pipe centre point with your pencil. 

2. Apply masking tape over the cutting area to reduce the chance of chipping or cracking (dependent upon the material of your bath panel).

3. Using your hole saw, drill slowly using a medium speed, and let the saw cut gradually. Pause occasionally to prevent any heat build-up (if acrylic). 

Larger shapes (or traps/valves):

This method is best to use on irregular shapes like a trap or shut-off valve. 

1. Firstly, make sure you are using the correct blade for the material of the bath panel. If it’s acrylic, you’ll need to use a fine-tooth blade (for plastic). If it’s MDF/wood, then you’ll need a fine wood blade (which will give you a cleaner cut).

2. Drill a starter hole inside your marked cut line so you can fit your jigsaw blade in.

3. Cut slowly keeping the base plate flat without forcing the blade. Let it move at its own pace and remember to take your time. If it starts melting (for acrylic), then you are going too fast.

Note: If you have an MDF bath panel, it’s important to always seal the cut edge after with a primer, glue or varnish