Double cut folder with variable knife mounting locations on cutting cylinders

A method of cutting a web into variable length signatures comprising the steps of:

• perforating a web with a first cutting cylinder pair and cutting the web into signatures having a first length with a second cutting cylinder pair, wherein each cutting cylinder pair includes a plurality of knife mounting locations and a plurality of cutting rubber locations, each knife mounting location configured to hold a knife box, wherein a first subset of the plurality of knife mounting locations each have a knife box secured therein, and a second subset of the plurality of knife mounting locations does not have a knife box or an anvil secured therein;
• on the first cutting cylinder pair and on the second cutting cylinder pair, removing one or more of the knife boxes from the first subset of knife mounting locations and securing one or more knife boxes into respective ones of the second subset of knife mounting locations, and thereafter;
• perforating a web with the first cutting cylinder pair and cutting the web into signatures having a second length with the second cutting cylinder pair;
• wherein the first cylinder pair includes a first knife cylinder and a first anvil cylinder, and the second cylinder pair includes a second knife cylinder and a second anvil cylinder and the first and second knife cylinders have a same diameter as a blanket cylinder transferring an image to the web.